Solar-cell module with in-laminate diodes and external-connection mechanisms mounted to respective edge regions

ABSTRACT

A solar-cell module. The solar-cell module includes a plurality of solar cells that are electrically coupled together. The solar-cell module further includes an in-laminate-diode assembly electrically coupled with the plurality of solar cells. The in-laminate-diode assembly is configured to prevent power loss. The solar-cell module also includes a protective structure at least partially encapsulating the plurality of solar cells. In addition, the solar-cell module includes a plurality of external-connection mechanisms mounted to a respective plurality of edge regions of the protective structure. An external-connection mechanism of the plurality of external-connection mechanisms is configured to enable collection of current from the plurality of solar cells and to allow interconnection with at least one other external device.

TECHNICAL FIELD

Embodiments of the present invention relate generally to the field ofphotovoltaic technology.

BACKGROUND

In the quest for renewable sources of energy, photovoltaic technologyhas assumed a preeminent position as a cheap renewable source of cleanenergy. In particular, solar cells based on the compound semiconductorcopper indium gallium diselenide (CIGS) used as an absorber layer offergreat promise for thin-film solar cells having high efficiency and lowcost. Of comparable importance to the technology used to fabricatethin-film solar cells themselves, is the technology used to collectcurrent from solar-cell modules and to interconnect one solar-cellmodule to another to form a solar-cell array.

Solar-cell arrays are impacted by parasitic series resistances, just assolar-cell modules and thin-film solar cells. A significant challenge isthe development of solar-cell-module current-collection andinterconnection schemes that minimize this effect in solar-cell arrays.Reliability and efficiency of solar-cell modules protected from shadingeffects is equally important as it determines the useful life andperformance of solar-cell arrays.

SUMMARY

Embodiments of the present invention include a solar-cell module. Thesolar-cell module includes a plurality of solar cells that areelectrically coupled together. The solar-cell module further includes anin-laminate-diode assembly electrically coupled with the plurality ofsolar cells. The in-laminate-diode assembly is configured to preventpower loss. The solar-cell module also includes a protective structureat least partially encapsulating the plurality of solar cells. Inaddition, the solar-cell module includes a plurality ofexternal-connection mechanisms mounted to a respective plurality of edgeregions of the protective structure. An external-connection mechanism ofthe plurality of external-connection mechanisms is configured to enablecollection of current from the plurality of solar cells and to allowinterconnection with at least one other external device.

DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and form a part ofthis specification, illustrate embodiments of the invention and,together with the description, serve to explain the embodiments of theinvention:

FIG. 1A is a cross-sectional elevation view of a layer structure of asolar cell, in accordance with an embodiment of the present invention.

FIG. 1B is a schematic diagram of a model circuit of a solar cell,electrically connected to a load, in accordance with an embodiment ofthe present invention.

FIG. 2 is a schematic diagram of a model circuit of a solar-cell module,electrically connected to a load, that shows the interconnection ofsolar cells in the solar-cell module, in accordance with an embodimentof the present invention.

FIG. 3 is a schematic diagram of a model circuit of a solar-cell module,electrically connected to a load, that details model circuits ofinterconnect assemblies, in accordance with an embodiment of the presentinvention.

FIG. 4A is a schematic diagram of a model circuit of an interconnectassembly for connecting two solar cells of a solar-cell module, inaccordance with an embodiment of the present invention.

FIG. 4B is a plan view of the interconnect assembly of FIG. 4A thatshows the physical interconnection of two solar cells in the solar-cellmodule, in accordance with an embodiment of the present invention.

FIG. 4C is a cross-sectional, elevation view of the interconnectassembly of FIG. 4B that shows the physical interconnection of two solarcells in the solar-cell module, in accordance with an embodiment of thepresent invention.

FIG. 4D is a cross-sectional, elevation view of an alternativeinterconnect assembly for FIG. 4B that shows an edge-conforminginterconnect assembly for the physical interconnection of two solarcells in the solar-cell module, in accordance with an embodiment of thepresent invention.

FIG. 4E is a cross-sectional, elevation view of an alternativeinterconnect assembly for FIG. 4B that shows a shingled-solar-cellarrangement for the physical interconnection of two solar cells in thesolar-cell module, in accordance with an embodiment of the presentinvention.

FIG. 4F is a plan view of an alternative interconnect assembly for FIG.4A that shows the physical interconnection of two solar cells in thesolar-cell module, in accordance with an embodiment of the presentinvention.

FIG. 5A is a plan view of the combined applicable carrier film,interconnect assembly that shows the physical arrangement of a tracewith respect to a top carrier film and a bottom carrier film in thecombined applicable carrier film, interconnect assembly, in accordancewith an embodiment of the present invention.

FIG. 5B is a cross-sectional, elevation view of the combined applicablecarrier film, interconnect assembly of FIG. 5A that shows the physicalarrangement of a trace with respect to a top carrier film in thecombined applicable carrier film, interconnect assembly prior todisposition on a solar cell, in accordance with an embodiment of thepresent invention.

FIG. 5C is a cross-sectional, elevation view of the interconnectassembly of FIG. 5B that shows the physical arrangement of a trace withrespect to a top carrier film in the combined applicable carrier film,interconnect assembly after disposition on a solar cell, in accordancewith an embodiment of the present invention.

FIG. 6A is a plan view of an integrated busbar-solar-cell-currentcollector that shows the physical interconnection of a terminating solarcell with a terminating busbar in the integratedbusbar-solar-cell-current collector, in accordance with an embodiment ofthe present invention.

FIG. 6B is a cross-sectional, elevation view of the integratedbusbar-solar-cell-current collector of FIG. 6A that shows the physicalinterconnection of the terminating solar cell with the terminatingbusbar in the integrated busbar-solar-cell-current collector, inaccordance with an embodiment of the present invention.

FIG. 7A is a combined cross-sectional elevation and perspective view ofa roll-to-roll, interconnect-assembly fabricator for fabricating theinterconnect assembly from a first roll of top carrier film and from adispenser of conductive-trace material, in accordance with an embodimentof the present invention.

FIG. 7B is a combined cross-sectional elevation and perspective view ofa roll-to-roll, laminated-interconnect-assembly fabricator forfabricating a laminated-interconnect assembly from the first roll of topcarrier film, from a second roll of bottom carrier film and from thedispenser of conductive-trace material, in accordance with an embodimentof the present invention.

FIG. 8 is flow chart illustrating a method for roll-to-roll fabricationof an interconnect assembly, in accordance with an embodiment of thepresent invention.

FIG. 9 is flow chart illustrating a method for interconnecting two solarcells, in accordance with an embodiment of the present invention.

FIG. 10 is a plan view of a solar-cell module combined withexternal-connection mechanism mounted to respective edge regions andin-laminate-diode assembly, in accordance with an embodiment of thepresent invention.

FIG. 11A is a schematic diagram of a diode used to by-pass currentaround a solar cell and electrically coupled in parallel with the solarcell, in accordance with an embodiment of the present invention.

FIG. 11B is a schematic diagram of a diode used to by-pass currentaround a plurality of solar cells and electrically coupled in parallelwith the plurality of solar cells that are electrically coupled inparallel, in accordance with an embodiment of the present invention.

FIG. 11C is a schematic diagram of a diode used to by-pass currentaround a plurality of solar cells and electrically coupled in parallelwith the plurality of solar cells that are electrically coupled inseries, in accordance with an embodiment of the present invention.

FIG. 11D is a schematic diagram of a diode used to by-pass currentaround a plurality of solar cells and electrically coupled in parallelwith the plurality of solar cells that are electrically coupled inseries and in parallel, in accordance with an embodiment of the presentinvention.

FIG. 12A is a plan view of a solar-cell array including a plurality ofsolar-cell modules combined with centrally-mounted junction boxes andin-laminate-diode assemblies, in accordance with an embodiment of thepresent invention.

FIG. 12B is a plan view of a solar-cell array including a plurality ofsolar-cell modules combined with external-connection mechanism mountedto respective edge regions and in-laminate-diode assemblies, inaccordance with an embodiment of the present invention.

FIG. 13 is a combined perspective-plan and expanded view ofin-laminate-diode sub-assemblies showing an arrangement of a diodetherein, in accordance with an embodiment of the present invention.

FIG. 14 is a combined plan and perspective view of a lead at a cutcorner of a back glass of a solar-cell module, in accordance with anembodiment of the present invention.

FIG. 15A is a plan view of a first junction box of a first solar-cellmodule with a female receptacle and a second junction box of a secondsolar-cell module with a male connector configured to allowinterconnection with the first solar-cell module, in accordance with anembodiment of the present invention.

FIG. 15B is a plan view of an interconnector with a male connectorintegrally attached to the second junction box of the second solar-cellmodule and configured to allow interconnection with the first junctionbox with the female receptacle of the first solar-cell module, inaccordance with an embodiment of the present invention.

FIG. 15C is a plan view of an interconnector with a female receptacleintegrally attached to the first junction box of the first solar-cellmodule, and of the interconnector with the male connector integrallyattached to the second junction box of the second solar-cell module andconfigured to allow interconnection with the first junction box, inaccordance with an embodiment of the present invention.

The drawings referred to in this description should not be understood asbeing drawn to scale except if specifically noted.

DESCRIPTION OF EMBODIMENTS

Reference will now be made in detail to the various embodiments of thepresent invention. While the invention will be described in conjunctionwith the various embodiments, it will be understood that they are notintended to limit the invention to these embodiments. On the contrary,the invention is intended to cover alternatives, modifications andequivalents, which may be included within the spirit and scope of theinvention as defined by the appended claims.

Furthermore, in the following description of embodiments of the presentinvention, numerous specific details are set forth in order to provide athorough understanding of the present invention. However, it should beappreciated that embodiments of the present invention may be practicedwithout these specific details. In other instances, well known methods,procedures, and components have not been described in detail as not tounnecessarily obscure embodiments of the present invention.

Overview

Section I describes in detail various embodiments of the presentinvention for an interconnect assembly (Sub-Section A), methods offabricating the same (Sub-Section B), methods of interconnectingsolar-cells (Sub-Section C), as well as a trace used in solar cells(Sub-Section D), that are incorporated as elements of the solar-cellmodule combined with in-laminate diodes and external-connectionmechanisms mounted to respective edge regions. FIGS. 1 through 9illustrate specific embodiments of the present invention for theinterconnect assembly so incorporated as an element of the solar-cellmodule combined with in-laminate diodes and external-connectionmechanisms mounted to respective edge regions. In particular, FIGS.2, 3and 4A through 4F illustrate specific embodiments of the presentinvention for the interconnection of solar cells in the solar-cellmodule of the present invention. Moreover, FIGS. 6A and 6B illustratespecific embodiments of the present invention for an integratedbusbar-solar-cell-current collector that show the physicalinterconnection of a terminating solar cell in a solar-cell module ofembodiments of the present invention.

Section II provides a detailed description of various embodiments of thepresent invention for the solar-cell module combined with in-laminatediodes and external-connection mechanisms mounted to respective edgeregions. FIGS. 10 through 15 illustrate detailed arrangements of elementcombinations for the solar-cell module combined with in-laminate diodesand external-connection mechanisms mounted to respective edge regions,in accordance with embodiments of the present invention.

Section I: Sub-Section A: Physical Description of Embodiments of thePresent Invention for an Interconnect Assembly

With reference to FIG. 1A, in accordance with an embodiment of thepresent invention, a cross-sectional elevation view of a layer structureof a solar cell 100A is shown. The solar cell 100A includes a metallicsubstrate 104. In accordance with an embodiment of the presentinvention, an absorber layer 112 is disposed on the metallic substrate104; the absorber layer 112 may include a layer of the material copperindium gallium diselenide (CIGS) having the chemical formulaCu(In_(1-x)Ga_(x))Se₂, where x may be a decimal less than one butgreater than zero that determines the relative amounts of theconstituents, indium, In, and gallium, Ga. Alternatively, semiconductorshaving the chalcopyrite crystal structure, for example, chemicallyhomologous compounds with the compound CIGS having the chalcopyritecrystal structure, in which alternative elemental constituents aresubstituted for Cu, In, Ga, and/or Se, may be used as the absorber layer112. Moreover, in embodiments of the present invention, it should benoted that semiconductors, such as silicon and cadmium telluride, aswell as other semiconductors, may be used as the absorber layer 112.

As shown, the absorber layer 112 includes a p-type portion 112 a and ann-type portion 112 b. As a result, a pn homojunction 112 c is producedin the absorber layer 112 that serves to separate charge carriers thatare created by light incident on the absorber layer 112. To facilitatethe efficient conversion of light energy to charge carriers in theabsorber layer 112, the composition of the p-type portion 112 a of theabsorber layer 112 may vary with depth to produce a graded band gap ofthe absorber layer 112. Alternatively, the absorber layer 112 mayinclude only a p-type chalcopyrite semiconductor layer, such as a CIGSmaterial layer, and a pn heterojunction may be produced between theabsorber layer 112 and an n-type layer, such as a metal oxide, metalsulfide or metal selenide, disposed on its top surface in place of then-type portion 112 b shown in FIG. 1A. However, embodiments of thepresent invention are not limited to pn junctions fabricated in themanner described above, but rather a generic pn junction produced eitheras a homojunction in a single semiconductor material, or alternatively aheterojunction between two different semiconductor materials, is withinthe spirit and scope of embodiments of the present invention. Moreover,in embodiments of the present invention, it should be noted thatsemiconductors, such as silicon and cadmium telluride, as well as othersemiconductors, may be used as the absorber layer 112.

In accordance with an embodiment of the present invention, on thesurface of the n-type portion 112 b of the absorber layer 112, one ormore transparent electrically conductive oxide (TCO) layers 116 aredisposed, for example, to provide a means for collection of current fromthe absorber layer 112 for conduction to an external load. As usedherein, it should be noted that the phrase “collection of current”refers to collecting current carriers of either sign, whether they bepositively charged holes or negatively charged electrons; for thestructure shown in FIG. 1A in which the TCO layer is disposed on then-type portion 112 b, the current carriers collected under normaloperating conditions are negatively charged electrons; but, embodimentsof the present invention apply, without limitation thereto, to solarcell configurations where a p-type layer is disposed on an n-typeabsorber layer, in which case the current carriers collected may bepositively charged holes. The TCO layer 116 may include zinc oxide, ZnO,or alternatively a doped conductive oxide, such as aluminum zinc oxide(AZO), Al_(x)Zn_(1-x)O_(y), and indium tin oxide (ITO),In_(x)Sn_(1-x)O_(y), where the subscripts x and y indicate that therelative amount of the constituents may be varied. Alternatively, theTCO layer 116 may be composed of a plurality of conductive oxide layers.These TCO layer materials may be sputtered directly from an oxidetarget, or alternatively the TCO layer may be reactively sputtered in anoxygen atmosphere from a metallic target, such as zinc, Zn, Al—Zn alloy,or In−Sn alloy targets. For example, the zinc oxide may be deposited onthe absorber layer 112 by sputtering from a zinc-oxide-containingtarget; alternatively, the zinc oxide may be deposited from azinc-containing target in a reactive oxygen atmosphere in areactive-sputtering process. The reactive-sputtering process may providea means for doping the absorber layer 112 with an n-type dopant, such aszinc, Zn, or indium, In, to create a thin n-type portion 112 b, if thepartial pressure of oxygen is initially reduced during the initialstages of sputtering a metallic target, such as zinc, Zn, or indium, In,and the layer structure of the solar cell 100A is subsequently annealedto allow interdiffusion of the zinc, Zn, or indium, In, with CIGSmaterial used as the absorber layer 112. Alternatively, sputtering acompound target, such as a metal oxide, metal sulfide or metal selenide,may also be used to provide the n-type layer, as described above, on thep-type portion 112 a of the absorber layer 112.

With further reference to FIG. 1A, in accordance with the embodiment ofthe present invention, a conductive backing layer 108 may be disposedbetween the absorber layer 112 and the metallic substrate 104 to providea diffusion barrier between the absorber layer 112 and the metallicsubstrate 104. The conductive backing layer 108 may include molybdenum,Mo, or other suitable metallic layer having a low propensity forinterdiffusion with an absorber layer 112, such as one composed of CIGSmaterial, as well as a low diffusion coefficient for constituents of thesubstrate. Moreover, the conductive backing layer 108 may provide otherfunctions in addition to, or independent of, the diffusion-barrierfunction, for example, a light-reflecting function, for example, as alight-reflecting layer, to enhance the efficiency of the solar cell, aswell as other functions. The embodiments recited above for theconductive backing layer 108 should not be construed as limiting thefunction of the conductive backing layer 108 to only those recited, asother functions of the conductive backing layer 108 are within thespirit and scope of embodiments of the present invention, as well.

With reference now to FIG. 1B, in accordance with an embodiment of thepresent invention, a schematic diagram of a model circuit 100B of asolar cell that is electrically connected to a load is shown. The modelcircuit 100B of the solar cell includes a current source 158 thatgenerates a photocurrent, i_(L). As shown in FIG. 1A, the current source158 is such as to produce counterclockwise electrical current, orequivalently an clockwise electron-flow, flowing around each of theloops of the circuit shown; embodiments of the present invention alsoapply, without limitation thereto, to solar-cell circuits in which theelectrical current flows in a clockwise direction, or equivalentlyelectrons flow in a counterclockwise direction. The photocurrent, i_(L),is produced when a plurality of incident photons, light particles, ofwhich one example photon 154 with energy, hν, is shown, produceelectron-hole pairs in the absorber layer 112 and these electron-holepairs are separated by the pn homojunction 112 c, or in the alternative,by a pn heterojunction as described above. It should be appreciated thatthe energy, hν, of each incident photon of the plurality of photonsshould exceed the band-gap energy, E_(g), that separates the valenceband from the conduction band of the absorber layer 112 to produce suchelectron-hole pairs, which result in the photocurrent, i_(L).

The model circuit 100B of the solar cell further includes a diode 162,which corresponds to recombination currents, primarily at the pnhomojunction 112 c, that are shunted away from the connected load. Asshown in FIG. 1B, the diode is shown having a polarity consistent withelectrical current flowing counterclockwise, or equivalentlyelectron-flow clockwise, around the loops of the circuit shown;embodiments of the present invention apply, without limitation thereto,to a solar cell in which the diode of the model circuit has the oppositepolarity in which electrical current flows clockwise, or equivalentlyelectron-flow flows counterclockwise, around the loops of the circuitshown. In addition, the model circuit 100B of the solar cell includestwo parasitic resistances corresponding to a shunt resistor 166 withshunt resistance, R_(Sh), and to a series resistor 170 with seriesresistance, R_(S). The solar cell may be connected to a load representedby a load resistor 180 with load resistance, R_(L). Thus, the circuitelements of the solar cell include the current source 158, the diode 162and the shunt resistor 166 connected across the current source 158, andthe series resistor 170 connected in series with the load resistor 180across the current source 158, as shown. As the shunt resistor 166, likethe diode 162, are connected across the current source 158, these twocircuit elements are associated with internal electrical currents withinthe solar cell shunted away from useful application to the load. As theseries resistor 170 connected in series with the load resistor 180 areconnected across the current source 158, the series resistor 170 isassociated with internal resistance of the solar cell that limits theelectrical current to the load.

With further reference to FIG. 1B, it should be recognized that theshunt resistance may be associated with surface leakage currents thatfollow paths at free surfaces that cross the pn homojunction 112 c; freesurfaces are usually found at the edges of the solar cell along the sidewalls of the device that define its lateral dimensions; such freesurfaces may also be found at discontinuities in the absorber layer 112that extend past the pn homojunction 112 c. The shunt resistance mayalso be associated with shunt defects which may be present that shuntelectrical current away from the load. A small value of the shuntresistance, R_(Sh), is undesirable as it lowers the open circuitvoltage, V_(OC), of the solar cell, which directly affects theefficiency of the solar cell. Moreover, it should also be recognizedthat the series resistance, R_(S), is associated with: the contactresistance between the p-type portion 112 a and the conductive backinglayer 108, the bulk resistance of the p-type portion 112 a, the bulkresistance of the n-type portion 112 b, the contact resistance betweenthe n-type portion 112 b and TCO layer 116, and other components, suchas conductive leads, and connections in series with the load. Theselatter sources of series resistance, conductive leads, and connectionsin series with the load, are germane to embodiments of the presentinvention as interconnect assemblies, which is subsequently described. Alarge value of the series resistance, R_(S), is undesirable as it lowersthe short circuit current, I_(SC), of the solar cell, which alsodirectly affects the efficiency of the solar cell.

With reference now to FIG. 2, in accordance with an embodiment of thepresent invention, a schematic diagram of a model circuit 200 of asolar-cell module 204 that is coupled to a load is shown. The load isrepresented by a load resistor 208 with load resistance, R_(L), asshown. The solar-cell module 204 of the model circuit 200 includes aplurality of solar cells: a first solar cell 210 including a currentsource 210 a that generates a photocurrent, i_(L1), produced by examplephoton 214 with energy, hν₁, a diode 210 b and a shunt resistor 210 cwith shunt resistance, R_(Sh1); a second solar cell 230 including acurrent source 230 a that generates a photocurrent, i_(L2), produced byexample photon 234 with energy, hν₂, a diode 230 b and a shunt resistor230 c with shunt resistance, R_(Sh2); and, a terminating solar cell 260including a current source 260 a that generates a photocurrent, i_(L3),produced by example photon 264 with energy, hν_(n), a diode 260 b and ashunt resistor 260 c with shunt resistance, R_(Shn). Parasitic seriesinternal resistances of the respective solar cells 210, 230 and 260 havebeen omitted from the schematic diagram to simplify the discussion.Instead, series resistors with series resistances, R_(S1), R_(S2) andR_(Sn) are shown disposed in the solar-cell module 204 of the modelcircuit 200 connected in series with the solar cells 210, 230 and 260and the load resistor 208.

As shown in FIGS. 2 and 3, the current sources are such as to producecounterclockwise electrical current, or equivalently an clockwiseelectron-flow, flowing around each of the loops of the circuit shown;embodiments of the present invention also apply, without limitationthereto, to solar-cell circuits in which the electrical current flows ina clockwise direction, or equivalently electrons flow in acounterclockwise direction. Similarly, as shown in FIGS. 2 and 3, thediode is shown having a polarity consistent with electrical currentflowing counterclockwise, or equivalently electron-flow clockwise,around the loops of the circuit shown; embodiments of the presentinvention apply, without limitation thereto, to a solar cell in whichthe diode of the model circuit has the opposite polarity in whichelectrical current flows clockwise, or equivalently electron-flow flowscounterclockwise, around the loops of the circuit shown.

With further reference to FIG. 2, in accordance with an embodiment ofthe present invention, the series resistors with series resistancesR_(S1), and R_(S2) correspond to interconnect assemblies 220 and 240,respectively. Series resistor with series resistance, R_(S1),corresponding to interconnect assembly 220 is shown configured both tocollect current from the first solar cell 210 and to interconnectelectrically to the second solar cell 230. Series resistor with seriesresistance, R_(Sn), corresponds to an integrated solar-cell, currentcollector 270. The ellipsis 250 indicates additional solar cells andinterconnect assemblies (not shown) coupled in alternating pairs inseries in model circuit 200 that make up the solar-cell module 204.Also, in series with the solar cells 210, 230 and 260 are a first busbar284 and a terminating busbar 280 with series resistances R_(B1) andR_(B2), respectively, that carry the electrical current generated bysolar-cell module 204 to the load resistor 208. The series resistor withresistance R_(Sn), corresponding to the integrated solar-cell, currentcollector 270, and R_(B2), corresponding to the terminating busbar 280,in combination correspond to a integrated busbar-solar-cell-currentcollector 290 coupling the terminating solar cell 260 with the loadresistor 208. In addition, series resistor with resistance R_(S1),corresponding to interconnect assembly 220, and first solar cell 210 incombination correspond to a combined solar-cell, interconnect assembly294.

As shown in FIG. 2 and as used herein, it should be noted that thephrases “to collect current,” “collecting current” and “currentcollector” refer to collecting, transferring, and/or transmittingcurrent carriers of either sign, whether they be positively chargedholes or negatively charged electrons; for the structures shown in FIGS.1A-B, 2, 3, 4A-F, 5A-C and 6A-B, in which an interconnect assembly isdisposed above and electrically coupled to an n-type portion of thesolar cell, the current carriers collected under normal operatingconditions are negatively charged electrons. Moreover, embodiments ofthe present invention apply, without limitation thereto, to solar cellconfigurations where a p-type layer is disposed on an n-type absorberlayer, in which case the current carriers collected may be positivelycharged holes, as would be the case for solar cells modeled by diodesand current sources of opposite polarity to those of FIGS. 1A-B, 2, 3,4A-F, 5A-C and 6A-B. Therefore, in accordance with embodiments of thepresent invention, a current collector and associated interconnectassembly that collects current may, without limitation thereto, collect,transfer, and/or transmit charges associated with an electrical current,and/or charges associated with an electron-flow, as for either polarityof the diodes and current sources described herein, and thus for eitherconfiguration of a solar cell with an n-type layer disposed on andelectrically coupled to a p-type absorber layer or a p-type layerdisposed on and electrically coupled to an n-type absorber layer, aswell as other solar cell configurations.

With further reference to FIG. 2, in accordance with an embodiment ofthe present invention, the series resistances of the interconnectassemblies 220 and 240, integrated solar-cell, current collector 270,and the interconnect assemblies included in ellipsis 250 can have asubstantial net series resistance in the model circuit 200 of thesolar-cell module 204, unless the series resistances of the interconnectassemblies 220 and 240, integrated solar-cell, current collector 270,and the interconnect assemblies included in ellipsis 250 are made small.If a large plurality of solar cells are connected in series, the shortcircuit current of the solar-cell module, I_(SCM), may be reduced, whichalso directly affects the solar-cell-module efficiency analogous to themanner in which solar-cell efficiency is reduced by a parasitic seriesresistance, R_(S), as described above with reference to FIG. 1.Embodiments of the present invention provide for diminishing the seriesresistances of the interconnect assemblies 220 and 240, integratedsolar-cell, current collector 270, and the interconnect assembliesincluded in ellipsis 250.

With reference now to FIG. 3, in accordance with embodiments of thepresent invention, a schematic diagram of a model circuit 300 of asolar-cell module 304 is shown that illustrates embodiments of thepresent invention such that the series resistances of the interconnectassemblies 320 and 340, integrated solar-cell, current collector 370,and the interconnect assemblies included in ellipsis 350 are made small.The solar-cell module 304 is coupled to a load represented by a loadresistor 308 with load resistance, R_(L), as shown. The solar-cellmodule 304 of the model circuit 300 includes a plurality of solar cells:a first solar cell 310 including a current source 310 a that generates aphotocurrent, i_(L1), produced by example photon 314 with energy, hν₁, adiode 310 b and a shunt resistor 310 c with shunt resistance, R_(Sh1); asecond solar cell 330 including a current source 330 a that generates aphotocurrent, i_(L2), produced by example photon 334 with energy, hν₂, adiode 330 b and a shunt resistor 330 c with shunt resistance, R_(Sh2);and, a terminating solar cell 360 including a current source 360 a thatgenerates a photocurrent, i_(L3), produced by example photon 364 withenergy, hν_(n), a diode 360 b and a shunt resistor 360 c with shuntresistance, R_(Shn).

With further reference to FIG. 3, in accordance with an embodiment ofthe present invention, the interconnect assemblies 320 and 340 and theintegrated solar-cell, current collector 370, with respective equivalentseries resistances R_(S1), R_(S2) and R_(Sn) are shown disposed in thesolar-cell module 304 of the model circuit 300 connected in series withthe solar cells 310, 330 and 360 and the load resistor 308. The ellipsis350 indicates additional solar cells and interconnect assemblies (notshown) coupled in alternating pairs in series in model circuit 300 thatmake up the solar-cell module 304. Also, in series with the solar cells310, 330 and 360 are a first busbar 384 and a terminating busbar 380with series resistances R_(B1) and R_(B2), respectively, that carry theelectrical current generated by solar-cell module 304 to the loadresistor 308. The integrated solar-cell, current collector 370 withresistance R_(Sn), and the series resistor with series resistanceR_(B2), corresponding to the terminating busbar 380, in combinationcorrespond to an integrated busbar-solar-cell-current collector 390coupling the terminating solar cell 360 with the load resistor 308. Inaddition, interconnect assembly 320 with resistance, R_(S2), and solarcell 310 in combination correspond to a combined solar-cell,interconnect assembly 394.

With further reference to FIG. 3, in accordance with embodiments of thepresent invention, the interconnect assembly 320 includes a traceincluding a plurality of electrically conductive portions, identifiedwith resistors 320 a, 320 b, 320 c, and 320 m with respectiveresistances, r_(P11), r_(P12), r_(P13) and r_(P1m), and the ellipsis 320i indicating additional resistors (not shown). It should be noted thatalthough the plurality of electrically conductive portions of the traceare modeled here as discrete resistors the interconnection with solarcell 330 is considerably more complicated involving the distributedresistance in the TCO layer of the solar cell, which has been omittedfor the sake of elucidating functional features of embodiments of thepresent invention. Therefore, it should be understood that embodimentsof the present invention may also include, without limitation thereto,the effects of such distributed resistances on the trace. The pluralityof electrically conductive portions, without limitation thereto,identified with resistors 320 a, 320 b, 320 c, 320 i, and 320 m, areconfigured both to collect current from the first solar cell 310 and tointerconnect electrically to the second solar cell 330. The plurality ofelectrically conductive portions, identified with resistors 320 a, 320b, 320 c, 320 i, and 320 m, are configured such that uponinterconnecting the first solar cell 310 and the second solar cell 330the plurality of electrically conductive portions are connectedelectrically in parallel between the first solar cell 310 and the secondsolar cell 330.

Thus, in accordance with embodiments of the present invention, theplurality of electrically conductive portions is configured such thatequivalent series resistance, R_(S1), of the interconnect assembly 320including the parallel network of resistors 320 a, 320 b, 320 c, 320 i,and 320 m, is less than the resistance of any one resistor in theparallel network. Therefore, upon interconnecting the first solar cell310 with the second solar cell 330, the equivalent series resistance,R_(S1), of the interconnect assembly 320, is given approximately,omitting the effects of distributed resistances at the interconnectswith the first and second solar cells 310 and 330, by the formula for aplurality of resistors connected electrically in parallel, viz.R_(S1)=1/[Σ(1/r_(P1i))], where r_(P1i) is the resistance of the ithresistor in the parallel-resistor network, and the sum, Σ, is taken overall of the resistors in the network from i=1 to m. Hence, by connectingthe first solar cell 310 to the second solar cell 330, with theinterconnect assembly 320, the series resistance, R_(S1), of theinterconnect assembly 320 can be reduced lowering the effective seriesresistance between solar cells in the solar-cell module 304 improvingthe solar-cell-module efficiency.

Moreover, in accordance with embodiments of the present invention, theconfiguration of the plurality of electrically conductive portions dueto this parallel arrangement of electrically conductive portions betweenthe first solar cell 310 and the second solar cell 330 provides aredundancy of electrical current carrying capacity betweeninterconnected solar cells should one of the plurality of electricallyconductive portions become damaged, or its reliability become impaired.Thus, embodiments of the present invention provide that the plurality ofelectrically conductive portions is configured such that solar-cellefficiency is substantially undiminished in an event that any one of theplurality of electrically conductive portions is conductively impaired,because the loss of electrical current through any one electricallyconductive portion will be compensated for by the plurality of otherparallel electrically conductive portions coupling the first solar cell310 with the second solar cell 330. It should be noted that as usedherein the phrase, “substantially undiminished,” with respect tosolar-cell efficiency means that the solar-cell efficiency is notreduced below an acceptable level of productive performance.

With further reference to FIG. 3, in accordance with embodiments of thepresent invention, the interconnect assembly 340 includes a traceincluding a plurality of electrically conductive portions identifiedwith resistors 340 a, 340 b, 340 c, and 340 m with respectiveresistances, r_(P21), r_(P22) , r_(P23) and r_(P2m), and the ellipsis340 i indicating additional resistors (not shown). The plurality ofelectrically conductive portions, without limitation thereto, identifiedwith resistors 340 a, 340 b, 340 c, 340 i, and 340 m, are configuredboth to collect current from a first solar cell 330 and to interconnectelectrically to a second solar cell, in this case a next adjacent one ofthe plurality of solar cells represented by ellipsis 350. From thisexample, it should be clear that for embodiments of the presentinvention a first solar cell and a second solar cell refer, withoutlimitation thereto, to just two adjacent solar cells configured inseries in the solar-cell module, and need not be limited to a solar celllocated first in line of a series of solar cells in a solar-cell module,nor a solar cell located second in line of a series of solar cells in asolar-cell module. The resistors 340 a, 340 b, 340 c, 340 i, and 340 m,are configured such that upon interconnecting the first solar cell 330and the second solar cell, in this case the next adjacent solar cell ofthe plurality of solar cells represented by ellipsis 350, the resistors340 a, 340 b, 340 c, 340 i, and 340 m, are coupled electrically inparallel between the first solar cell 330 and the second solar cell, thenext adjacent solar cell of the plurality of solar cells represented byellipsis 350.

Thus, in accordance with embodiments of the present invention, theplurality of electrically conductive portions is configured such thatseries resistance, R_(S2), of the interconnect assembly 340 includingthe parallel network of resistors 340 a, 340 b, 340 c, 340 i, and 340 m,is less than the resistance of any one resistor in the network. Hence,the series resistance, R_(S2), of the interconnect assembly 340 can bereduced lowering the effective series resistance between solar cells inthe solar-cell module improving the solar-cell-module efficiency of thesolar-cell module 304. Moreover, the plurality of electricallyconductive portions, identified with resistors 340 a, 340 b, 340 c, 340i, and 340 m, may be configured such that solar-cell efficiency issubstantially undiminished in an event that any one of the plurality ofelectrically conductive portions is conductively impaired.

With further reference to FIG. 3, in accordance with embodiments of thepresent invention, the combined solar-cell, interconnect assembly 394includes the first solar cell 310 and the interconnect assembly 320; theinterconnect assembly 320 includes a trace disposed above a light-facingside of the first solar cell 310, the trace further including aplurality of electrically conductive portions, identified with resistors320 a, 320 b, 320 c, and 320 m with respective resistances, r_(P21),r_(P22) , r_(P23) and r_(P2m), and the ellipsis 320 i indicatingadditional resistors (not shown). All electrically conductive portionsof the plurality of electrically conductive portions, without limitationthereto, identified with resistors 320 a, 320 b, 320 c, 320 i, and 320m, are configured to collect current from the first solar cell 310 andto interconnect electrically to the second solar cell 330. In addition,the plurality of electrically conductive portions, identified withresistors 320 a, 320 b, 320 c, 320 i, and 320 m, may be configured suchthat solar-cell efficiency is substantially undiminished in an eventthat any one of the plurality of electrically conductive portions isconductively impaired. Also, any of the plurality of electricallyconductive portions, identified with resistors 320 a, 320 b, 320 c, 320i, and 320 m, may be configured to interconnect electrically to thesecond solar cell 330.

With further reference to FIG. 3, in accordance with embodiments of thepresent invention, the integrated busbar-solar-cell-current collector390 includes the terminating busbar 380 and the integrated solar-cell,current collector 370. The integrated solar-cell, current collector 370includes a trace including a plurality of electrically conductiveportions, identified with resistors 370 a, 370 b, 370 l, and 370 m withrespective resistances, r_(Pn1), r_(Pn2), r_(Pn1) and r_(Pnm), and theellipsis 370 i indicating additional resistors (not shown). Theplurality of electrically conductive portions, without limitationthereto, identified with resistors 370 a, 370 b, 370 i, 370 l and 370 m,are configured both to collect current from the first solar cell 310 andto interconnect electrically to the terminating busbar 380. Theresistors 370 a, 370 b, 370 i, 370 l and 370 m, are coupled electricallyin parallel between the terminating solar cell 360 and the terminatingbusbar 380 series resistor with series resistance, R_(B2). Thus, theplurality of electrically conductive portions is configured such thatseries resistance, R_(Sn), of the interconnect assembly 340 includingthe parallel network of resistors 370 a, 370 b, 370 i, 370 l and 370 m,is less than the resistance of any one resistor in the network.

In accordance with embodiments of the present invention, the integratedsolar-cell, current collector 370 includes a plurality of integratedpairs of electrically conductive, electrically parallel trace portions.Resistors 370 a, 370 b, 370 l and 370 m with respective resistances,r_(Pn1), r_(Pn2), r_(Pn1) and r_(Pnm), and the ellipsis 370 i indicatingadditional resistors (not shown) form such a plurality of integratedpairs of electrically conductive, electrically parallel trace portionswhen suitably paired as adjacent pair units connected electricallytogether as an integral unit over the terminating solar cell 360. Forexample, one such pair of the plurality of integrated pairs ofelectrically conductive, electrically parallel trace portions is pair ofresistors 370 a and 370 b connected electrically together as an integralunit over the terminating solar cell 360, as shown. The plurality ofintegrated pairs of electrically conductive, electrically parallel traceportions are configured both to collect current from the terminatingsolar cell 360 and to interconnect electrically to the terminatingbusbar 380. Moreover, the plurality of integrated pairs of electricallyconductive, electrically parallel trace portions is configured such thatsolar-cell efficiency is substantially undiminished in an event that anyone electrically conductive, electrically parallel trace portion, forexample, either one, but not both, of the resistors 370 a and 370 b ofthe integral pair, of the plurality of integrated pairs of electricallyconductive, electrically parallel trace portions is conductivelyimpaired.

With further reference to FIG. 3, in accordance with embodiments of thepresent invention, the solar-cell module 304 includes the first solarcell 310, at least the second solar cell 330 and the interconnectassembly 320 disposed above a light-facing side of an absorber layer ofthe first solar cell 310. The interconnect assembly 320 includes a traceincluding a plurality of electrically conductive portions, identifiedwith resistors 320 a, 320 b, 320 c, and 320 m with respectiveresistances, r_(P11), r_(P12) , r_(P13) and r_(P1m), and the ellipsis320 i indicating additional resistors (not shown). The plurality ofelectrically conductive portions is configured both to collect currentfrom the first solar cell 310 and to interconnect electrically to thesecond solar cell 330. The plurality of electrically conductive portionsis configured such that solar-cell efficiency is substantiallyundiminished in an event that any one of the plurality of electricallyconductive portions is conductively impaired.

With reference now to FIGS. 4A, 4B and 4C, in accordance withembodiments of the present invention, a schematic diagram of a modelcircuit 400A of an interconnect assembly 420 connecting a first solarcell 410 to a second solar cell 430 of a solar-cell module 404 is shown.The interconnect assembly 420 includes a trace including a plurality ofelectrically conductive portions, identified with resistors 420 a, 420b, 420 c, and 420 m with respective resistances, r_(P11), r_(P12) ,r_(P13) and r_(P1m), and the ellipsis 420 i indicating additionalresistors (not shown). The plurality of electrically conductiveportions, without limitation thereto, identified with resistors 420 a,420 b, 420 c, 420 i, and 420 m, are configured both to collect currentfrom the first solar cell 410 and to interconnect electrically to thesecond solar cell 430. The plurality of electrically conductiveportions, identified with resistors 420 a, 420 b, 420 c, 420 i, and 420m, are configured such that, upon interconnecting the first solar cell410 and the second solar cell 430, the plurality of electricallyconductive portions are connected electrically in parallel between thefirst solar cell 410 and the second solar cell 430. The plurality ofelectrically conductive portions is configured such that equivalentseries resistance, R_(S1), of the interconnect assembly 420 includingthe parallel network of resistors 420 a, 420 b, 420 c, 420 i, and 420 m,is less than the resistance of any one resistor in the parallel network.Therefore, by connecting the first solar cell 410 to the second solarcell 430, with the interconnect assembly 420, the series resistance,R_(S1), of the interconnect assembly 420 can be reduced lowering theeffective series resistance between solar cells in the solar-cell module404 improving the solar-cell-module efficiency.

Moreover, in accordance with embodiments of the present invention, theconfiguration of the plurality of electrically conductive portions dueto this parallel arrangement of electrically conductive portions betweenthe first solar cell 410 and the second solar cell 430 provides aredundancy of electrical current carrying capacity betweeninterconnected solar cells should any one of the plurality ofelectrically conductive portions become damaged, or its reliabilitybecome impaired. Thus, embodiments of the present invention provide thatthe plurality of electrically conductive portions is configured suchthat solar-cell efficiency is substantially undiminished in an eventthat any one of the plurality of electrically conductive portions isconductively impaired, because the loss of electrical current throughany one electrically conductive portion will be compensated for by theplurality of the unimpaired parallel electrically conductive portionscoupling the first solar cell 410 with the second solar cell 430. Itshould be noted that as used herein the phrase, “substantiallyundiminished,” with respect to solar-cell efficiency means that thesolar-cell efficiency is not reduced below an acceptable level ofproductive performance. In addition, in accordance with embodiments ofthe present invention, the plurality of electrically conductive portionsmay be configured in pairs of electrically conductive portions, forexample, identified with resistors 420 a and 420 b. Thus, the pluralityof electrically conductive portions may be configured such thatsolar-cell efficiency is substantially undiminished even in an eventthat, in every pair of electrically conductive portions of the pluralityof electrically conductive portions, one electrically conductive portionof the pair is conductively impaired. In accordance with embodiments ofthe present invention, each member of a pair of electrically conductiveportions may be electrically equivalent to the other member of the pair,but need not be electrically equivalent to the other member of the pair,it only being necessary that in an event one member, a first member, ofthe pair becomes conductively impaired the other member, a secondmember, is configured such that solar-cell efficiency is substantiallyundiminished.

With further reference to FIG. 4B and 4C, in accordance with embodimentsof the present invention, a plan view 400B of the interconnect assembly420 of FIG. 4A is shown that details the physical interconnection of twosolar cells 410 and 430 in the solar-cell module 404. The solar-cellmodule 404 includes the first solar cell 410, at least the second solarcell 430 and the interconnect assembly 420 disposed above a light-facingside 416 of the absorber layer of the first solar cell 410. Theinterconnect assembly 420 includes a trace including a plurality ofelectrically conductive portions 420 a, 420 b, 420 c, 420 i and 420 m,previously identified herein with the resistors 420 a, 420 b, 420 c, 420i and 420 m described in FIG. 400A, where the ellipsis of 420 iindicates additional electrically conductive portions (not shown). Theplurality of electrically conductive portions 420 a, 420 b, 420 c, 420 iand 420 m is configured both to collect current from the first solarcell 410 and to interconnect electrically to the second solar cell 430.The plurality of electrically conductive portions 420 a, 420 b, 420 c,420 i and 420 m is configured such that solar-cell efficiency issubstantially undiminished in an event that any one of the plurality ofelectrically conductive portions 420 a, 420 b, 420 c, 420 i and 420 m isconductively impaired.

With further reference to FIG. 4B, in accordance with embodiments of thepresent invention, the detailed configuration of the plurality ofelectrically conductive portions 420 a, 420 b, 420 c, 420 i and 420 m isshown. The plurality of electrically conductive portions 420 a, 420 b,420 c, 420 i and 420 m further includes a first portion 420 a of theplurality of electrically conductive portions 420 a, 420 b, 420 c, 420 iand 420 m configured both to collect current from the first solar cell410 and to interconnect electrically to the second solar cell 430 and asecond portion 420 b of the plurality of electrically conductiveportions 420 a, 420 b, 420 c, 420 i and 420 m configured both to collectcurrent from the first solar cell 410 and to interconnect electricallyto the second solar cell 430. The first portion 420 a includes a firstend 420 p distal from the second solar cell 430. Also, the secondportion 420 b includes a second end 420 q distal from the second solarcell 430. The second portion 420 b is disposed proximately to the firstportion 420 a and electrically connected to the first portion 420 a suchthat the first distal end 420 p is electrically connected to the seconddistal end 420 q, for example, at first junction 420 r, or by a linkingportion, such that the second portion 420 b is configured electricallyin parallel to the first portion 420 a when configured to interconnectto the second solar cell 430.

With further reference to FIG. 4B, in accordance with embodiments of thepresent invention, the plurality of electrically conductive portions 420a, 420 b, 420 c, 420 i and 420 m may further include the second portion420 b including a third end 420 s distal from the first solar cell 410and a third portion 420 c of the plurality of electrically conductiveportions 420 a, 420 b, 420 c, 420 i and 420 m configured both to collectcurrent from the first solar cell 410 and to interconnect electricallyto the second solar cell 430. The third portion 420 c includes a fourthend 420 t distal from the first solar cell 410. The third portion 420 cis disposed proximately to the second portion 420 b and electricallyconnected to the second portion 420 b such that the third distal end 420s is electrically connected to the fourth distal end 420 t, for example,at second junction 420 u, or by a linking portion, such that the thirdportion 420 c is configured electrically in parallel to the secondportion 420 b when configured to interconnect with the first solar cell430.

With further reference to FIG. 4B and 4C, in accordance with embodimentsof the present invention, it should be noted that the nature of theparallel connection between electrically conductive portionsinterconnecting a first solar cell and a second solar cell is such that,for distal ends of electrically conductive portions not directly joinedtogether, without limitation thereto, the metallic substrate of a secondsolar cell and a TCO layer of the first solar cell may provide thenecessary electrical coupling. For example, distal ends 420 v and 420 sare electrically coupled through a low resistance connection through ametallic substrate 430 c of second solar cell 430. Similarly, forexample, distal ends 420 w and 420 q are electrically coupled throughthe low resistance connection through the TCO layer 410 b of first solarcell 410.

With further reference to FIG. 4B, in accordance with embodiments of thepresent invention, an open-circuit defect 440 is shown such that secondportion 420 b is conductively impaired. FIG. 4B illustrates the mannerin which the plurality of electrically conductive portions 420 a, 420 b,420 c, 420 i and 420 m is configured such that solar-cell efficiency issubstantially undiminished in an event that any one of the plurality ofelectrically conductive portions 420 a, 420 b, 420 c, 420 i and 420 m isconductively impaired, for example, second portion 420 b. An arrow 448indicates the nominal electron-flow through a third portion 420 c of theplurality of electrically conductive portions 420 a, 420 b, 420 c, 420 iand 420 m essentially unaffected by open-circuit defect 440. In theabsence of open-circuit defect 440, an electron-flow indicated by arrow448 would normally flow through any one electrically conductive portionof the plurality of electrically conductive portions 420 a, 420 b, 420c, 420 i and 420 m, in particular, second portion 420 b. However, whenthe open-circuit defect 440 is present, this electron-flow divides intotwo portions shown by arrows 442 and 444: arrow 442 corresponding tothat portion of the normal electron-flow flowing to the right along thesecond portion 420 b to the second solar cell 430, and arrow 444corresponding to that portion of the normal electron-flow flowing to theleft along the second portion 420 b to the first portion 420 a and thento the right along the first portion 420 a to the second solar cell 430.Thus, the net electron-flow represented by arrow 446 flowing to theright along the first portion 420 a is consequently larger than whatwould normally flow to the right along the first portion 420 a to thesecond solar cell 430 in the absence of the open-circuit defect 440.

It should be noted that open-circuit defect 440 is for illustrationpurposes only and that embodiments of the present invention compensatefor other types of defects in an electrically conductive portion, ingeneral, such as, without limitation to: a delamination of anelectrically conductive portion from the first solar cell 410, corrosionof an electrically conductive portion, and even complete loss of anelectrically conductive portion. In accordance with embodiments of thepresent invention, in the event a defect completely conductively impairsan electrically conductive portion, the physical spacing betweenadjacent electrically conductive portions, identified with double-headedarrow 449, may be chosen such that solar-cell efficiency issubstantially undiminished. Nevertheless, embodiments of the presentinvention embrace, without limitation thereto, other physical spacingsbetween adjacent electrically conductive portions in the event defectsare less severe than those causing a complete loss of one of theelectrically conductive portions.

With further reference to FIG. 4B, in accordance with embodiments of thepresent invention, the plurality of electrically conductive portions 420a, 420 b, 420 c, 420 i and 420 m may be connected electrically in seriesto form a single continuous electrically conductive line. Moreover, thetrace that includes the plurality of electrically conductive portions420 a, 420 b, 420 c, 420 i and 420 m may be disposed in a serpentinepattern such that the interconnect assembly 420 is configured to collectcurrent from the first solar cell 410 and to interconnect electricallyto the second solar cell 430, as shown.

With further reference to FIG. 4C, in accordance with embodiments of thepresent invention, a cross-sectional, elevation view 400C of theinterconnect assembly 420 is shown that further details the physicalinterconnection of two solar cells 410 and 430 in the solar-cell module404. Projections 474 and 478 of planes orthogonal to both of the viewsin FIGS. 4B and 4C, and coincident with the ends of the plurality ofelectrically conductive portions 420 a, 420 b, 420 c, 420 i and 420 mshow the correspondence between features of the plan view 400B of FIG.4B and features in the cross-sectional, elevation view 400C of FIG. 4C.Also, it should be noted that although the solar-cell module 404 isshown with separation 472 between the first solar cell 410 and thesecond solar cell 430, there need not be such separation 472 between thefirst solar cell 410 and the second solar cell 430. As shown in FIG. 4Band 4C, a combined solar-cell, interconnect assembly 494 includes thefirst solar cell 410 and the interconnect assembly 420. The interconnectassembly 420 includes the trace disposed above the light-facing side 416of the first solar cell 410, the trace further including the pluralityof electrically conductive portions 420 a, 420 b, 420 c, 420 i and 420m. All electrically conductive portions of the plurality of electricallyconductive portions 420 a, 420 b, 420 c, 420 i and 420 m are configuredto collect current from the first solar cell 410 and to interconnectelectrically to the second solar cell 430. In addition, the plurality ofelectrically conductive portions 420 a, 420 b, 420 c, 420 i and 420 mmay be configured such that solar-cell efficiency is substantiallyundiminished in an event that any one of the plurality of electricallyconductive portions 420 a, 420 b, 420 c, 420 i and 420 m is conductivelyimpaired. Also, any of the plurality of electrically conductive portions420 a, 420 b, 420 c, 420 i and 420 m may be configured to interconnectelectrically to the second solar cell 430. The first solar cell 410 ofthe combined solar-cell, interconnect assembly 494 may include ametallic substrate 410 c and an absorber layer 410 a. The absorber layer410 a of the first solar cell 410 may include copper indium galliumdiselenide (CIGS). Alternatively, other semiconductors having thechalcopyrite crystal structure, for example, chemically homologouscompounds with the compound CIGS having the chalcopyrite crystalstructure, in which alternative elemental constituents are substitutedfor Cu, In, Ga, and/or Se, may be used as the absorber layer 410 a.Moreover, in embodiments of the present invention, it should be notedthat semiconductors, such as silicon and cadmium telluride, as well asother semiconductors, may be used as the absorber layer 410 a.

With further reference to FIG. 4C, in accordance with embodiments of thepresent invention, the plurality of electrically conductive portions 420a, 420 b, 420 c, 420 i and 420 m of the combined solar-cell,interconnect assembly 494 further includes the first portion 420 a ofthe plurality of electrically conductive portions 420 a, 420 b, 420 c,420 i and 420 m configured to collect current from the first solar cell410 and the second portion 420 b of the plurality of electricallyconductive portions 420 a, 420 b, 420 c, 420 i and 420 m configured tocollect current from the first solar cell 410. The first portion 420 aincludes the first end 420 p distal from an edge 414 of the first solarcell 410. The second portion 420 b includes the second end 420 q distalfrom the edge 414 of the first solar cell 410. The second portion 420 bis disposed proximately to the first portion 420 a and electricallyconnected to the first portion 420 a such that the first distal end 420p is electrically connected to the second distal end 420 q such that thesecond portion 420 b is configured electrically in parallel to the firstportion 420 a when configured to interconnect to the second solar cell430.

With further reference to FIG. 4C, in accordance with embodiments of thepresent invention, the interconnect assembly 420 further includes a topcarrier film 450. The top carrier film 450 includes a firstsubstantially transparent, electrically insulating layer coupled to thetrace and disposed above a top portion of the trace. The firstsubstantially transparent, electrically insulating layer allows forforming a short-circuit-preventing portion 454 at an edge 434 of thesecond solar cell 430. The first substantially transparent, electricallyinsulating layer allows for forming the short-circuit-preventing portion454 at the edge 434 of the second solar cell 430 to prevent the firstportion 420 a from short circuiting an absorber layer 430 a of thesecond solar cell 430 in the event that the first portion 420 a bucklesand rides up a side 432 of second solar cell 430. The edge 434 islocated at the intersection of the side 432 of the second solar cell 430and a back side 438 of the second solar cell 430 that couples with theplurality of electrically conductive portions 420 a, 420 b, 420 c, 420 iand 420 m, for example, first portion 420 a as shown. The second solarcell 430 may include the absorber layer 430 a, a TCO layer 430 b, andthe metallic substrate 430 c; a backing layer (not shown) may also bedisposed between the absorber layer 430 a and the metallic substrate 430c. Above a light-facing side 436 of the second solar cell 430, anintegrated busbar-solar-cell-current collector (not shown in FIG. 4C,but which is shown in FIGS. 6A and 6B) may be disposed and coupled tothe second solar cell 430 to provide interconnection with a load (notshown). Alternatively, above the light-facing side 436 of the secondsolar cell 430, another interconnect assembly (not shown) may bedisposed and coupled to the second solar cell 430 to provideinterconnection with additional solar-cells (not shown) in thesolar-cell module 404.

With further reference to FIG. 4C, in accordance with embodiments of thepresent invention, the interconnect assembly 420 further includes abottom carrier film 460. The bottom carrier film 460 may include asecond electrically insulating layer coupled to the trace and disposedbelow a bottom portion of the trace. Alternatively, The bottom carrierfilm 460 may include a carrier film selected from a group consisting ofa second electrically insulating layer, a structural plastic layer, anda metallic layer, and is coupled to the trace and is disposed below abottom portion of the trace. The second electrically insulating layerallows for forming an edge-protecting portion 464 at the edge 414 of thefirst solar cell 410. Alternatively, a supplementary isolation strip(not shown) of a third electrically insulating layer may be disposedbetween the bottom carrier film 460 and the first portion 420 a of theplurality of electrically conductive portions 420 a, 420 b, 420 c, 420 iand 420 m, or alternatively between the bottom carrier film 460 and theedge 414, to provide additional protection at the edge 414. Thesupplementary isolation strip may be as wide as 5 millimeters (mm) inthe direction of the double-headed arrow showing the separation 472, andmay extend along the full length of a side 412 of the first solar cell410. The edge 414 is located at the intersection of the side 412 of thefirst solar cell 410 and a light-facing side 416 of the first solar cell410 that couples with the plurality of electrically conductive portions420 a, 420 b, 420 c, 420 i and 420 m, for example, first portion 420 aas shown. The first solar cell 410 may include the absorber layer 410 a,the TCO layer 410 b, and the metallic substrate 410 c; a backing layer(not shown) may also be disposed between the absorber layer 410 a andthe metallic substrate 410 c. Below a back side 418 of the first solarcell 410, a first busbar (not shown) may be disposed and coupled to thefirst solar cell 410 to provide interconnection with a load (not shown).Alternatively, below the back side 418 of the first solar cell 410,another interconnect assembly (not shown) may be disposed and coupled tothe first solar cell 410 to provide interconnection with additionalsolar-cells (not shown) in the solar-cell module 404.

With reference now to FIGS. 4D and 4E, in accordance with embodiments ofthe present invention, cross-sectional, elevation views 400D and 400E,respectively, of two alternative interconnect assemblies that minimizethe separation 472 (see FIG. 4B) between the first solar cell 410 andthe second solar cell 430 to improve the solar-cell-module efficiency ofthe solar-cell module 404 are shown. In both examples shown in FIGS. 4Dand 4E, the side 412 of the first solar cell 410 essentially coincideswith the side 432 of the second solar cell 430. It should be noted thatas used herein the phrase, “essentially coincides,” with respect to theside 412 of the first solar cell 410 and the side 432 of the secondsolar cell 430 means that there is little or no separation 472 betweenthe first solar cell 410 and the second solar cell 430, and little or nooverlap of the first solar cell 410 with the second solar cell 430 sothat there is less wasted space and open area between the solar cells410 and 430, which improves the solar-collection efficiency of thesolar-cell module 404 resulting in improved solar-cell-moduleefficiency. FIG. 4D shows an edge-conforming interconnect assembly forthe physical interconnection of the two solar cells 410 and 430 in thesolar-cell module 404. FIG. 4E shows a shingled-solar-cell arrangementfor the physical interconnection of the two solar cells 410 and 430 inthe solar-cell module 404. For both the edge-conforming interconnectassembly of FIG. 4D and the shingled-solar-cell arrangement of FIG. 4E,the interconnect assembly 420 further includes the bottom carrier film460. The bottom carrier film 460 includes a second electricallyinsulating layer coupled to the trace and disposed below a bottomportion of the trace. Alternatively, The bottom carrier film 460 mayinclude a carrier film selected from a group consisting of a secondelectrically insulating layer, a structural plastic layer, and ametallic layer, and is coupled to the trace and is disposed below abottom portion of the trace. The second electrically insulating layerallows for forming the edge-protecting portion 464 at the edge 414 ofthe first solar cell 410. In the case of the edge-conforminginterconnect assembly shown in FIG. 4D, the bottom carrier film 460 andthe first portion 420 a of the interconnect assembly 420 may berelatively flexible and compliant allowing them to wrap around the edge414 and down the side 412 of the first solar cell 410, as shown. Theedge 414 is located at the intersection of the side 412 of the firstsolar cell 410 and the light-facing side 416 of the first solar cell 410that couples with the plurality of electrically conductive portions 420a, 420 b, 420 c, 420 i and 420 m, for example, first portion 420 a asshown. The first solar cell 410 may include the absorber layer 410 a, aTCO layer 410 b, and the metallic substrate 410 c; a backing layer (notshown) may also be disposed between the absorber layer 410 a and themetallic substrate 410 c. Below the back side 418 of the first solarcell 410, another interconnect assembly (not shown) or first busbar (notshown) may be disposed and coupled to the first solar cell 410 asdescribed above for FIG. 4C. If an additional solar cell (not shown) isinterconnected to the back side 418 of the first solar cell 410 as inthe shingled-solar-cell arrangement of FIG. 4E, the first solar cell 410would be pitched upward at its left-hand side and interconnected toanother interconnect assembly similar to the manner in which the secondsolar cell 430 is shown interconnected with solar cell 410 at side 412in FIG. 4E.

With further reference to FIGS. 4D and 4E, in accordance withembodiments of the present invention, the interconnect assembly 420further includes the top carrier film 450. The top carrier film 450includes a first substantially transparent, electrically insulatinglayer coupled to the trace and disposed above a top portion of thetrace. The first substantially transparent, electrically insulatinglayer allows for forming the short-circuit-preventing portion 454 at theedge 434 of the second solar cell 430 to prevent the first portion 420 afrom short circuiting the absorber layer 430 a of the second solar cell430 in the event that the first portion 420 a rides up the side 432 ofsecond solar cell 430. The edge 434 is located at the intersection ofthe side 432 of the second solar cell 430 and the back side 438 of thesecond solar cell 430 that couples with the plurality of electricallyconductive portions 420 a, 420 b, 420 c, 420 i and 420 m, for example,first portion 420 a as shown. In the case of the edge-conforminginterconnect assembly shown in FIG. 4D, the top carrier film 450 may berelatively flexible and compliant allowing it to follow the conformationof the bottom carrier film 460 and the first portion 420 a of theinterconnect assembly 420 underlying it that wrap around the edge 414and down the side 412 of the first solar cell 410, as shown. The secondsolar cell 430 may include the absorber layer 430 a, the TCO layer 430b, and the metallic substrate 430 c; a backing layer (not shown) mayalso be disposed between the absorber layer 430 a and the metallicsubstrate 430 c. Also, in the case of the edge-conforming interconnectassembly, the absorber layer 430 a, TCO layer 430 b, and metallicsubstrate 430 c of the second solar cell 430 may be relatively flexibleand compliant allowing them to follow the conformation of the underlyinginterconnect assembly 420 that wraps around the edge 414 and down theside 412 of the first solar cell 410. Above the light-facing side 436 ofthe second solar cell 430, an integrated busbar-solar-cell-currentcollector (not shown in FIG. 4C, but which is shown in FIGS. 6A and 6B),or alternatively another interconnect assembly (not shown), may bedisposed on and coupled to the second solar cell 430, as described abovefor FIG. 4C.

With reference now to FIG. 4F, in accordance with embodiments of thepresent invention, a plan view 400F of an alternative interconnectassembly for the interconnect assembly 420 of FIG. 4A is shown thatdetails the physical interconnection of two solar cells 410 and 430 inthe solar-cell module 404. The solar-cell module 404 includes the firstsolar cell 410, at least the second solar cell 430 and the interconnectassembly 420 disposed above the light-facing side 416 of the absorberlayer of the first solar cell 410. The edges 414 and 434 of the solarcells 410 and 430 may be separated by the separation 472 as shown inFIG. 4F; or alternatively, the edges 414 and 434 of the solar cells 410and 430 may essentially coincide as discussed above for FIGS. 4D and 4E.The interconnect assembly 420 includes a trace including a plurality ofelectrically conductive portions 420 a, 420 b, 420 c, 420 i and 420 m,previously identified herein with the resistors 420 a, 420 b, 420 c, 420i and 420 m described in FIG. 400A, where the ellipsis of 420 iindicates additional electrically conductive portions (not shown). Theplurality of electrically conductive portions 420 a, 420 b, 420 c, 420 iand 420 m is configured both to collect current from the first solarcell 410 and to interconnect electrically to the second solar cell 430.The plurality of electrically conductive portions 420 a, 420 b, 420 c,420 i and 420 m is configured such that solar-cell efficiency issubstantially undiminished in an event that any one of the plurality ofelectrically conductive portions 420 a, 420 b, 420 c, 420 i and 420 m isconductively impaired.

With further reference to FIG. 4F, in accordance with embodiments of thepresent invention, the detailed configuration of the plurality ofelectrically conductive portions 420 a, 420 b, 420 c, 420 i and 420 m isshown without electrically connecting trace portions, for example,junctions formed in the trace or linking portions of the trace. Forexample, in the case where electrically connecting trace portions of thetrace have been cut away, removed, or are otherwise absent, from thedistal ends of the plurality of electrically conductive portions 420 a,420 b, 420 c, 420 i and 420 m, as shown in FIG. 4F. The plurality ofelectrically conductive portions 420 a, 420 b, 420 c, 420 i and 420 mmay be linked together instead indirectly by the TCO layer 410 b of thefirst solar cell 410 at distal ends of the trace disposed over the firstsolar cell 410, for example, first distal end 420 p of first portion 420a and second distal end 420 q of second portion 420 b by portions of theTCO layer 410 b of the first solar cell 410 that lie in between thedistal ends 420 p and 420 q. In like fashion, the distal ends 420 w and420 q are electrically coupled through the low resistance connectionthrough the TCO layer 410 b of first solar cell 410. Similarly, theplurality of electrically conductive portions 420 a, 420 b, 420 c, 420 iand 420 m may be linked together instead indirectly by the metallicsubstrate 430 c, or intervening backing layer (not shown), of the firstsolar cell 430 at distal ends of the trace disposed under the secondsolar cell 430, for example, third distal end 420 s of second portion420 b and fourth distal end 420 t of third portion 420 c by portions ofthe metallic substrate 430 c of the second solar cell 430 that lie inbetween the distal ends 420 s and 420 t. In like fashion, the distalends 420 v and 420 s are electrically coupled through a low resistanceconnection through the metallic substrate 430 c of second solar cell430.

With further reference to FIG. 4F, in accordance with embodiments of thepresent invention, the open-circuit defect 440 is shown such that secondportion 420 b is conductively impaired. FIG. 4F illustrates the mannerin which the plurality of electrically conductive portions 420 a, 420 b,420 c, 420 i and 420 m is configured such that solar-cell efficiency issubstantially undiminished in an event that any one of the plurality ofelectrically conductive portions 420 a, 420 b, 420 c, 420 i and 420 m isconductively impaired, for example, second portion 420 b. An arrow 480indicates the nominal electron-flow through an m-th portion 420 m of theplurality of electrically conductive portions 420 a, 420 b, 420 c, 420 iand 420 m essentially unaffected by open-circuit defect 440. In theabsence of open-circuit defect 440, an electron-flow indicated by arrow480 would normally flow through any one electrically conductive portionof the plurality of electrically conductive portions 420 a, 420 b, 420c, 420 i and 420 m, in particular, second portion 420 b. However, whenthe open-circuit defect 440 is present, portions of this electron-floware lost to adjacent electrically conductive portions 420 a and 420 cshown by arrows 484 a and 484 c; arrow 482 corresponds to that portionof the normal electron-flow flowing to the right along the secondportion 420 b to the second solar cell 430, and arrow 484 b correspondsto that portion of the normal electron-flow that would bridge theopen-circuit defect 440 by flowing through the higher resistance path ofthe TCO layer 410 b bridging across the two portions of second portion420 b on either side of the open-circuit defect 440. Thus, the netelectron-flow represented by arrow 486 flowing to the right along thefirst portion 420 a is consequently larger than what would normally flowto the right along the first portion 420 a to the second solar cell 430in the absence of the open-circuit defect 440; and, the netelectron-flow represented by arrow 488 flowing to the right along thethird portion 420 c is consequently larger than what would normally flowto the right along the third portion 420 c to the second solar cell 430in the absence of the open-circuit defect 440.

Moreover, in the case of the alternative interconnect assembly depictedin FIG. 4F, as stated before for the interconnect assembly depicted inFIG. 4B, it should again be noted that open-circuit defect 440 is forillustration purposes only and that embodiments of the present inventioncompensate for other types of defects in an electrically conductiveportion, in general, such as, without limitation to: a delamination ofan electrically conductive portion from the first solar cell 410,corrosion of an electrically conductive portion, and even complete lossof an electrically conductive portion. In accordance with embodiments ofthe present invention, in the event a defect completely conductivelyimpairs an electrically conductive portion, the physical spacing betweenadjacent electrically conductive portions, identified with double-headedarrow 449, may be chosen such that solar-cell efficiency issubstantially undiminished. Nevertheless, embodiments of the presentinvention embrace, without limitation thereto, other physical spacingsbetween adjacent electrically conductive portions in the event defectsare less severe than those causing a complete loss of one of theelectrically conductive portions.

With reference now to FIG. 5A, in accordance with embodiments of thepresent invention, a plan view 500A of the combined applicable carrierfilm, interconnect assembly 504 is shown. FIG. 5A shows the physicalarrangement of a trace 520 with respect to a top carrier film 550 and abottom carrier film 560 in the combined applicable carrier film,interconnect assembly 504. The combined applicable carrier film,interconnect assembly 504 includes the top carrier film 550 and thetrace 520 including a plurality of electrically conductive portions 520a, 520 b, 520 c, 520 d, 520 e, 520 f, 520 g, 520 m and 520 i, the lattercorresponding to the ellipsis indicating additional electricallyconductive portions (not shown). The plurality of electricallyconductive portions 520 a through 520 m is configured both to collectcurrent from a first solar cell 510 (shown in FIG. 5C) and tointerconnect electrically to a second solar cell (not shown). As shownin FIG. 5A, the plurality of electrically conductive portions 520 athrough 520 m run over the top of the first solar cell 510 on the leftand over an edge 514 of the first solar cell 510 to the right under anedge 534 of, and underneath, the second solar cell (not shown). The topcarrier film 550 includes a first substantially transparent,electrically insulating layer 550A (shown in FIG. 5B). The plurality ofelectrically conductive portions 520 a through 520 m is configured suchthat solar-cell efficiency is substantially undiminished in an eventthat any one of the plurality of electrically conductive portions 520 athrough 520 m is conductively impaired. It should be noted that as usedherein the phrase, “substantially transparent,” with respect to asubstantially transparent, electrically insulating layer means thatlight passes through the substantially transparent, electricallyinsulating layer with negligible absorption. The first substantiallytransparent, electrically insulating layer 550 a is coupled to the trace520 and disposed above a top portion of the trace 520 (shown in FIG. 5B)as indicated by the dashed portions of the trace 520 on the left of FIG.5A.

With reference now to FIGS.5B and 5C, in accordance with embodiments ofthe present invention, a cross-sectional, elevation view of the combinedapplicable carrier film, interconnect assembly 504 of FIG. 5A is shown.As shown in FIGS. 5B and 5C, the cross-section of the view is takenalong a cut parallel to the edge 514 of the first solar cell 510. Thecross-sectional, elevation view of FIG. 5B shows the physicalarrangement of the trace 520 with respect to the top carrier film 550 inthe combined applicable carrier film, interconnect assembly 504 prior todisposition on the first solar cell 510. On the other hand, thecross-sectional, elevation view of FIG. 5C shows the physicalarrangement of the trace 520 with respect to the top carrier film 550and the first solar cell 510 of the combined applicable carrier film,interconnect assembly 504 after it couples with the first solar cell510. The top carrier film 550 and the trace 520 are configured forapplying to a light-facing side of the first solar cell 510 both tocollect current from the first solar cell 510 and to interconnectelectrically to the second solar cell (not shown). The first solar cell510 may include an absorber layer 510 a, a TCO layer 510 b, and ametallic substrate 510 c; the backing layer (not shown) may also bedisposed between the absorber layer 510 a and the metallic substrate 510c. The first substantially transparent, electrically insulating layer550 a holds the trace 520 down in contact with the first solar cell 510and allows for forming a short-circuit-preventing portion at an edge ofthe second solar cell (not shown). The top carrier film 550 furtherincludes a first substantially transparent, adhesive medium 550 bcoupling the trace 520 to the substantially transparent, electricallyinsulating layer 550 a. As shown in FIG. 5B, prior to disposition on thefirst solar cell 510, the top carrier film 550 lies relatively flatacross the top portion of the trace 520, for example, as for theconformational state of the top carrier film 550 immediately afterroll-to-roll fabrication of the combined applicable carrier film,interconnect assembly 504. In contrast, after disposition on the firstsolar cell 510, the top carrier film 550 conforms to the top portion ofthe trace 520, as shown in FIG. 5B. The first substantially transparent,adhesive medium 550 b allows for coupling the trace 520 to the firstsolar cell 510 without requiring solder. The first substantiallytransparent, electrically insulating layer 550 a may include astructural plastic material, such as polyethylene terephthalate (PET).In accordance with embodiments of the present invention, a firstsubstantially transparent, adhesive medium such as first substantiallytransparent, adhesive medium 550 b may be included, without limitationthereto, in a top carrier film of: the combined applicable carrier film,interconnect assembly 504, the interconnect assembly 320, the integratedbusbar-solar-cell-current collector 690 (see FIG. 6B), the combinedsolar-cell, interconnect assembly 494, or the interconnect assembly 420of the solar-cell module 404.

With further reference to FIGS. 5A, 5B and 5C, in accordance withembodiments of the present invention, the combined applicable carrierfilm, interconnect assembly 504 further includes the bottom carrier film560. The bottom carrier film 560 includes a second electricallyinsulating layer, like 550 a, coupled to the trace 520 and disposedbelow a bottom portion of the trace 520, as indicated by the solid-lineportions of the trace 520 on the right of FIG. 5A. Alternatively, thebottom carrier film 560 may include a carrier film selected from a groupconsisting of a second electrically insulating layer, a structuralplastic layer, and a metallic layer, and is coupled to the trace 520 andis disposed below a bottom portion of the trace 520. The secondelectrically insulating layer, like 550 a, holds the trace 520 down incontact with a back side of the second solar cell (not shown) and allowsfor forming an edge-protecting portion at the edge 514 of the firstsolar cell 510. The bottom carrier film 560 further includes a secondadhesive medium, like 550 b, coupling the trace to the secondelectrically insulating layer, like 550 a. The second adhesive medium,like 550 b, allows for coupling the trace 520 to the back side of thesecond solar cell (not shown) without requiring solder. The secondelectrically insulating layer, like 550 a, includes a structural plasticmaterial, such as PET. In accordance with embodiments of the presentinvention, a second adhesive medium, like 550 b, may be included,without limitation thereto, in a bottom carrier film of: the combinedapplicable carrier film, interconnect assembly 504, the interconnectassembly 320, the combined solar-cell, interconnect assembly 494, or theinterconnect assembly 420 of the solar-cell module 404.

With further reference to FIGS. 5A, in accordance with embodiments ofthe present invention, the trace 520 may be disposed in a serpentinepattern that allows for collecting current from the first solar cell 510(shown in FIG. 5C) and electrically interconnecting to the second solarcell (not shown). It should be noted that neither the first solar cell510 nor the second solar cell (not shown) are shown in FIG. 5A so as notto obscure the structure of the combined applicable carrier film,interconnect assembly 504. As shown in FIG. 5A, the combined applicablecarrier film, interconnect assembly 504 includes the trace 520 includingthe plurality of electrically conductive portions 520 a through 520 mthat may run in a serpentine pattern back and forth between the firstsolar cell 510 and the second solar cell (not shown). The serpentinepattern is such that adjacent electrically conductive portions of theplurality of electrically conductive portions 520 a through 520 m areconfigured in pairs of adjacent electrically conductive portions: 520 aand 520 b, 520 c and 520 d, 520 e and 520 f, etc. The pairs of adjacentelectrically conductive portions may be configured in a regularrepeating pattern of equally spaced adjacent electrically conductiveportions. The trace 520 including the plurality of electricallyconductive portions 520 a through 520 m is disposed between the topcarrier film 550 disposed above a top portion of the trace 520 and thebottom carrier film 560 disposed below a bottom portion of the trace520. The first substantially transparent, electrically insulating layer550 a of top carrier film 550 and the second electrically insulatinglayer, or alternatively, structural plastic layer or metallic layer, ofbottom carrier film 560 are coupled to the trace 520 with a firstsubstantially transparent, adhesive medium 550 b and second adhesivemedium which also serve to couple the trace 520 to the first solar cell510, which may be located on the left, and the second solar cell, whichmay be located on the right. In the space between the two solar cells,between the edge 514 of the first solar cell and the edge 534 of thesecond solar cell, the trace is sandwiched between the two carrier films550 and 560; the overlapping region of the two carrier films 550 and 560extends somewhat beyond the respective edges 514 and 534 of the firstand second solar cells so as to form, respectively, an edge-protectingportion at the edge 514 of the first solar cell, and ashort-circuit-preventing portion at the edge 534 of the second solarcell, from the trace 520 that crosses the edges 514 and 534.

With further reference to FIGS. 5B and 5C, in accordance withembodiments of the present invention, the trace 520 may further includean electrically conductive line including a conductive core 520A with atleast one overlying layer 520B. In one embodiment of the presentinvention, the electrically conductive line may include the conductivecore 520A including a material having greater conductivity than nickel,for example, copper, with an overlying nickel layer 520B. In anotherembodiment of the present invention, electrically conductive line mayinclude the conductive core 520A including nickel without the overlyinglayer 520B. The electrically conductive line may also be selected from agroup consisting of a copper conductive core clad with a silvercladding, a copper conductive core clad with a nickel coating furtherclad with a silver cladding and an aluminum conductive core clad with asilver cladding.

With further reference to FIG. 5B and 5C, in accordance with embodimentsof the present invention, the trace 520 for collecting current from asolar cell, for example the first solar cell 510, may include anelectrically conductive line including the conductive core 520A, and theoverlying layer 520B that limits current flow to a proximate shuntdefect (not shown) in the solar cell. The proximate shunt defect may beproximately located in the vicinity of an electrical contact between theoverlying layer 520B of the electrically conductive line and the TCOlayer 510 b of the solar cell, for example, first solar cell 510. Theoverlying layer 520B of the electrically conductive line of the trace520 may further include an overlying layer 520B composed of nickel. Theconductive core 520A of the electrically conductive line of the trace520 may further include nickel. The conductive core 520A may alsoinclude a material selected from a group consisting of copper, silver,aluminum, and elemental constituents and alloys having high electricalconductivity, which may be greater than the electrical conductivity ofnickel. The TCO layer 510 b of the solar cell, for example first solarcell 510, may include a conductive oxide selected from a groupconsisting of zinc oxide, aluminum zinc oxide and indium tin oxide. Inaddition, the absorber layer 510 a, for example, absorber layer 112 ofFIG. 1A, of the solar cell, for example, first solar cell 510, mayinclude copper indium gallium diselenide (CIGS). Alternatively, inembodiments of the present invention, it should be noted thatsemiconductors, such as silicon, cadmium telluride, and chalcopyritesemiconductors, as well as other semiconductors, may be used as theabsorber layer 510 a. Moreover, an n-type layer, for example, n-typeportion 112 b of absorber layer 112 of FIG. 1A, of the solar cell, forexample, first solar cell 510, may be disposed on and electricallycoupled to a p-type absorber layer, for example, absorber layer 112 ofFIG. 1A, of the solar cell, for example, first solar cell 510, and then-type layer, for example, n-type portion 112 b of absorber layer 112 ofFIG. 1A, may be selected from a group consisting of a metal oxide, ametal sulfide and a metal selenide.

Although the trace 520 is shown as having a circular cross-sectionhaving a point-like contact with a solar cell, for example, with the TCOlayer 510 b, or, without limitation thereto, to a top surface, of thefirst solar cell 510, embodiments of the present inventions include,without limitation thereto, other cross-sectional profiles of the trace520, such as a profile including a flattened top portion and a flattenedbottom portion, so as to increase the contact area between the trace 520and a solar cell with which it makes contact. For example, a flattenedbottom portion of trace 520 increases the contact area with thelight-facing side of the first solar cell 510; on the other hand, aflattened top portion of trace 520 increases the contact area with aback side of an adjacent solar cell to which the plurality ofelectrically conductive portions 520 a through 520 m of the trace 520interconnects. In accordance with embodiments of the present invention,a trace, such as trace 520, may be included, without limitation thereto,in: the combined applicable carrier film, interconnect assembly 504, theinterconnect assembly 320, the integrated busbar-solar-cell-currentcollector 690 (see FIG. 6B), the combined solar-cell, interconnectassembly 494, or the interconnect assembly 420 of the solar-cell module404.

With reference now to FIG. 6A, in accordance with embodiments of thepresent invention, a plan view 600A of an integratedbusbar-solar-cell-current collector 690 is shown. FIG. 6A shows thephysical interconnection of a terminating solar cell 660 with aterminating busbar 680 of the integrated busbar-solar-cell-currentcollector 690. The integrated busbar-solar-cell-current collector 690includes the terminating busbar 680 and an integrated solar-cell,current collector 670. The integrated solar-cell, current collector 670includes a plurality of integrated pairs 670 a&b, 670 c&d, 670 e&f, 670g&h, and 670 l&m and 670 i, the ellipsis indicating additionalintegrated pairs (not shown), of electrically conductive, electricallyparallel trace portions 670 a-m. Throughout the following, therespective integrated pairs: 670 a and 670 b, 670 c and 670 d, 670 e and670 f, 670 g and 670 h, and 670 l and 670 m, are referred torespectively as: 670 a&b, 670 c&d, 670 e&f, 670 g&h, and 670 l&m; andthe electrically conductive, electrically parallel trace portions: 670a, 670 b, 670 c, 670 d, 670 e, 670 f, 670 g, 670 h, 670 l and 670 m, arereferred to as 670 a-m. The plurality of integrated pairs 670 a&b, 670c&c, 670 e&f, 670 g&h, 670 i and 670 l&m of electrically conductive,electrically parallel trace portions 670 a-m is configured both tocollect current from the terminating solar cell 660 and to interconnectelectrically to the terminating busbar 680. The plurality of integratedpairs 670 a&b, 670 c&c, 670 e&f, 670 g&h, 670 i and 670 l&m ofelectrically conductive, electrically parallel trace portions 670 a-m isconfigured such that solar-cell efficiency is substantially undiminishedin an event that any one electrically conductive, electrically paralleltrace portion, for example, 670 h, of the plurality of integrated pairs670 a&b, 670 c&c, 670 e&f, 670 g&h, 670 i and 670 l&m of electricallyconductive, electrically parallel trace portions 670 a-m is conductivelyimpaired.

With further reference to FIG. 6A and 6B, in accordance with embodimentsof the present invention, the plurality of integrated pairs 670 a&b, 670c&c, 670 e&f, 670 g&h, 670 i and 670 l&m of electrically conductive,electrically parallel trace portions 670 a-m further includes a firstelectrically conductive, electrically parallel trace portion 670 a of afirst integrated pair 670 a&b of the electrically conductive,electrically parallel trace portions 670 a-m configured both to collectcurrent from the terminating solar cell 660 and to interconnectelectrically to the terminating busbar 680, and a second electricallyconductive, electrically parallel trace portion 670 b of the firstintegrated pair 670 a&b of the electrically conductive, electricallyparallel trace portions 670 a-m configured both to collect current fromthe terminating solar cell 660 and to interconnect electrically to theterminating busbar 680. The first electrically conductive, electricallyparallel trace portion 670 a includes a first end 670 p distal from theterminating busbar 680 located parallel to a side 662 of the terminatingsolar cell 660. The second electrically conductive, electricallyparallel trace portion 670 b includes a second end 670 q distal from theterminating busbar 680. The second electrically conductive, electricallyparallel trace portion 670 b is disposed proximately to the firstelectrically conductive, electrically parallel trace portion 670 a andelectrically connected to the first electrically conductive,electrically parallel trace portion 670 a such that the first distal end670 p is electrically connected to the second distal end 670 q, forexample, at first junction 670 r, or by a linking portion, such that thesecond electrically conductive, electrically parallel trace portion 670b is configured electrically in parallel to the first electricallyconductive, electrically parallel trace portion 670 a when configured tointerconnect to the terminating busbar 680. In addition, in accordancewith embodiments of the present invention, the terminating busbar 680may be disposed above and connected electrically to extended portions,for example, 670 x and 670 y, of the plurality of integrated pairs 670a&b, 670 c&c, 670 e&f, 670 g&h, 670 i and 670 l&m of electricallyconductive, electrically parallel trace portions 670 a-m configured suchthat the terminating busbar 680 is configured to reduce shadowing of theterminating solar cell 660.

With further reference to FIG. 6A, in accordance with embodiments of thepresent invention, an open-circuit defect 640 is shown such that eighthelectrically conductive, electrically parallel trace portion 670 h isconductively impaired. FIG. 6A illustrates the manner in which theplurality of integrated pairs 670 a&b, 670 c&c, 670 e&f, 670 g&h and 670l&m of electrically conductive, electrically parallel trace portions 670a-m is configured such that solar-cell efficiency is substantiallyundiminished in an event that any one electrically conductive,electrically parallel trace portion, for example, eighth electricallyconductive, electrically parallel trace portion 670 h, of the pluralityof integrated pairs 670 a&b, 670 c&c, 670 e&f, 670 g&h and 670 l&m ofelectrically conductive, electrically parallel trace portions 670 a-m isconductively impaired. The arrow 648 indicates the nominal electron-flowthrough a sixth electrically conductive, electrically parallel traceportion 670 f of the plurality of integrated pairs 670 a&b, 670 c&c, 670e&f, 670 g&h and 670 l&m of electrically conductive, electricallyparallel trace portions 670 a-m essentially unaffected by open-circuitdefect 640. In the absence of open-circuit defect 640, an electron-flowindicated by arrow 648 would normally flow through any one electricallyconductive, electrically parallel trace portion of the plurality ofintegrated pairs 670 a&b, 670 c&c, 670 e&f, 670 g&h and 670 l&m ofelectrically conductive, electrically parallel trace portions 670 a-m,in particular, eighth electrically conductive, electrically paralleltrace portion 670 h. However, when the open-circuit defect 640 ispresent, this electron-flow divides into two portions shown by arrows642 and 644: arrow 642 corresponding to that portion of the normalelectron-flow flowing to the right along the eighth electricallyconductive, electrically parallel trace portion 670 h to the terminatingbusbar 680, and arrow 644 corresponding to that portion of the normalelectron-flow flowing to the left along the eighth electricallyconductive, electrically parallel trace portion 670 h to the seventhelectrically conductive, electrically parallel trace portion 670 g andthen to the right along the seventh electrically conductive,electrically parallel trace portion 670 g to the terminating busbar 680.Thus, the net electron-flow represented by arrow 646 flowing to theright along the seventh electrically conductive, electrically paralleltrace portion 670 g is consequently larger than what would normally flowto the right along the seventh electrically conductive, electricallyparallel trace portion 670 g to the terminating busbar 680 in theabsence of the open-circuit defect 640. It should be noted thatopen-circuit defect 640 is for illustration purposes only and thatembodiments of the present invention compensate for other types ofdefects in an electrically conductive, electrically parallel traceportion, in general, such as, without limitation to: a delamination ofan electrically conductive, electrically parallel trace portion from theterminating solar cell 660, corrosion of an electrically conductive,electrically parallel trace portion, and even complete loss of anelectrically conductive, electrically parallel trace portion. Inaccordance with embodiments of the present invention, in the event adefect completely conductively impairs an electrically conductive,electrically parallel trace portion, the physical spacing betweenadjacent electrically conductive, electrically parallel trace portions,identified with double-headed arrow 649, may be chosen such thatsolar-cell efficiency is substantially undiminished. Nevertheless,embodiments of the present invention embrace, without limitationthereto, other physical spacings between adjacent electricallyconductive, electrically parallel trace portions in the event defectsare less severe than those causing a complete loss of one of theelectrically conductive, electrically parallel trace portions.

With reference now to FIG. 6B and further reference to FIG. 6A, inaccordance with embodiments of the present invention, a cross-sectional,elevation view 600B of the integrated busbar-solar-cell-currentcollector 690 of FIG. 6A is shown. FIG. 6B shows the physicalinterconnection of the terminating solar cell 660 with the terminatingbusbar 680 in the integrated busbar-solar-cell-current collector 690. Inaccordance with embodiments of the present invention, theinterconnection approach employing a carrier film is also conducive tocoupling the integrated busbar-solar-cell-current collector 690 directlyto the terminating busbar 680 without requiring solder. Thus, theintegrated busbar-solar-cell-current collector 690 further includes atop carrier film 650. The top carrier film 650 includes a firstsubstantially transparent, electrically insulating layer (not shown, butlike 550 a of FIG. 5B) coupled to the plurality of integrated pairs 670a&b, 670 c&c, 670 e&f, 670 g&h, 670 i and 670 l&m of electricallyconductive, electrically parallel trace portions 670 a-m, for example,electrically conductive, electrically parallel trace portion 670 a, anddisposed above a top portion of the plurality of integrated pairs 670a&b, 670 c&c, 670 e&f, 670 g&h, 670 i and 670 l&m of electricallyconductive, electrically parallel trace portions 670 a-m.

With further reference to FIG. 6A and 6B, in accordance with embodimentsof the present invention, the top carrier film 650 further includes afirst adhesive medium (not shown, but like 550 b of FIGS. 5B and 5C)coupling the plurality of integrated pairs 670 a&b, 670 c&c, 670 e&f,670 g&h, 670 i and 670 l&m of electrically conductive, electricallyparallel trace portions 670 a-m to the electrically insulating layer(like 550 a of FIG. 5B). The first adhesive medium (like 550 b of FIGS.5B and 5C) allows for coupling the plurality of integrated pairs 670a&b, 670 c&c, 670 e&f, 670 g&h, 670 i and 670 l&m of electricallyconductive, electrically parallel trace portions 670 a-m to theterminating solar cell 660 without requiring solder. The terminatingsolar cell 660 may include an absorber layer 660 a, a TCO layer 660 b,and a metallic substrate 660 c; a backing layer (not shown) may also bedisposed between the absorber layer 660 a and the metallic substrate 660c. The plurality of integrated pairs of electrically conductive,electrically parallel trace portions 670 a-m may be connectedelectrically in series to form a single continuous electricallyconductive line (not shown). The single continuous electricallyconductive line may be disposed in a serpentine pattern (not shown, butlike the pattern of trace 520 in FIG. 5A) such that the integratedbusbar-solar-cell-current collector 690 is configured to collect currentfrom the terminating solar cell 660 and to interconnect electrically tothe terminating busbar 680. The plurality of integrated pairs 670 a&b,670 c&c, 670 e&f, 670 g&h, 670 i and 670 l&m of electrically conductive,electrically parallel trace portions 670 a-m may further include aplurality of electrically conductive lines (not shown, but like trace520 of FIG. 5B and 5C), any electrically conductive line of theplurality of electrically conductive lines selected from a groupconsisting of a copper conductive core clad with a silver cladding, acopper conductive core clad with a nickel coating further clad with asilver cladding and an aluminum conductive core clad with a silvercladding.

With further reference to FIG. 6A and 6B, in accordance with embodimentsof the present invention, integrated busbar-solar-cell-current collector690 may include a supplementary isolation strip (not shown) at an edge664 of the terminating solar cell 660 and running along the length ofthe side 662 to provide additional protection at the edge 664 and side662 of the terminating solar cell 660 from the extended portions, forexample, 670 x and 670 y, of the plurality of integrated pairs 670 a&b,670 c&c, 670 e&f, 670 g&h, 670 i and 670 l&m of electrically conductive,electrically parallel trace portions 670 a-m. In another embodiment ofthe present invention, the extended portions, for example, 670 x and 670y, may be configured (not shown) to provide stress relief and to allowfolding the terminating busbar 680 along edge 664 under a back side 668and at the side 662 of terminating solar cell 660, so that there is lesswasted space and open area between the terminating solar cell 660 of onemodule and the initial solar cell (not shown) of an adjacent module.Moreover, integrated busbar-solar-cell-current collector 690 may includea supplementary carrier-film strip (not shown) at the edge 664 of theterminating solar cell 660 and running along the length of the side 662disposed above and coupled to top carrier film 650 and the terminatingbusbar 680 to affix the terminating busbar 680 to the extended portions,for example, 670 x and 670 y. Alternatively, the integratedbusbar-solar-cell-current collector 690 may include the top carrier film650 extending over the top of the terminating busbar 680 and extendedportions, for example, 670 x and 670 y, to affix the terminating busbar680 to these extended portions. Thus, these latter two embodiments ofthe present invention provide a laminate including the terminatingbusbar 680 disposed between top carrier film 650, or alternatively thesupplementary carrier-film strip, and the supplementary isolation strip(not shown) along the edge 664 and side 662 of the terminating solarcell 660. Moreover, the top carrier film 650, or the supplementarycarrier-film strip, is conducive to connecting the terminating busbar680 without requiring solder to the plurality, itself, or to theextended portions, for example, 670 x and 670 y, of the plurality ofintegrated pairs 670 a&b, 670 c&c, 670 e&f, 670 g&h, 670 i and 670 l&mof electrically conductive, electrically parallel trace portions 670 a-m

With reference now to FIG. 7A, in accordance with embodiments of thepresent invention, a combined cross-sectional elevation and perspectiveview of a roll-to-roll, interconnect-assembly fabricator 700A is shown.FIG. 7A shows the roll-to-roll, interconnect-assembly fabricator 700Aoperationally configured to fabricate an interconnect assembly 720. Atop carrier film 716 including an electrically insulating layer, forexample a first substantially transparent, electrically insulatinglayer, is provided to roll-to-roll, interconnect-assembly fabricator700A in roll form from a first roll of material 714. The roll-to-roll,interconnect-assembly fabricator 700A includes an first unwinding spool710 upon which the first roll of material 714 of the top carrier film716 including the electrically insulating layer is mounted. As shown, aportion of the first roll of material 714 is unrolled. The unrolledportion of the top carrier film 716 including the electricallyinsulating layer passes to the right and is taken up on a take-up spool718 upon which it is rewound as a third roll 722 of interconnectassembly 720, after conductive-trace material 750 is provided from adispenser 754 and is laid down onto the unrolled portion of the topcarrier film 716 including the electrically insulating layer. Thedispenser 754 of conductive-trace material 750 may be a spool of wire,or some other container providing conductive-trace material. Theconductive-trace material 750 may be laid down onto the unrolled portionof the top carrier film 716 including the electrically insulating layerin an oscillatory motion, but without limitation to a strictlyoscillatory motion, indicated by double-headed arrow 758, to create afirst plurality of electrically conductive portions configured both tocollect current from a first solar cell and to interconnect electricallyto a second solar cell such that solar-cell efficiency is substantiallyundiminished in an event that any one of the first plurality ofelectrically conductive portions is conductively impaired. As shown inFIG. 7A, a portion of the electrically conductive portions overhang oneside of the top carrier film 716 to allow the electrically conductiveportions of the trace to interconnect electrically to the second solarcell on the exposed top side of the trace, while the exposed bottom sideof the trace, here shown as facing upward on the top carrier film 716,allows the electrically conductive portions of the trace in contact withthe top carrier film 716 to interconnect electrically to the first solarcell. Moreover, the conductive-trace material 750 may be disposed in aserpentine pattern to create the plurality of electrically conductiveportions configured both to collect current from the first solar celland to interconnect electrically to the second solar cell. The arrowsadjacent to the first unwinding spool 710, and the take-up spool 718indicate that these are rotating components of the roll-to-roll,interconnect-assembly fabricator 700A; the first unwinding spool 710,and the take-up spool 718 are shown rotating in clockwise direction, asindicated by the arrow-heads on the respective arrows adjacent to thesecomponents, to transport the unrolled portion of the first roll ofmaterial 714 from the first unwinding spool 710 on the left to thetake-up spool 718 on the right.

With reference now to FIG. 7B, in accordance with embodiments of thepresent invention, a combined cross-sectional elevation and perspectiveview of a roll-to-roll, laminated-interconnect-assembly fabricator 700Bis shown. FIG. 7A shows the roll-to-roll,laminated-interconnect-assembly fabricator 700B operationally configuredto fabricate a laminated-interconnect assembly 740. The roll-to-roll,laminated-interconnect-assembly fabricator 700B first fabricates theinterconnect assembly 720 shown on the left-hand side of FIG. 7B fromthe first roll of material 714 of the top carrier film 716 including theelectrically insulating layer and from conductive-trace material 750provided from dispenser 754. Then, the roll-to-roll,laminated-interconnect-assembly fabricator 700B continues fabrication ofthe laminated-interconnect assembly 740 by applying a bottom carrierfilm 736 from a second roll 734. The bottom carrier film 736 includes acarrier film selected from a group consisting of a second electricallyinsulating layer, a structural plastic layer, and a metallic layer, andis coupled to the conductive-trace material 750 and is disposed below abottom portion of the conductive-trace material 750. If a metallic layeris used for the bottom carrier film 736, a supplementary isolation strip(not shown) of a third electrically insulating layer is added to thelaminated-interconnect assembly 740 configured to allow interposition ofthe third electrically insulating layer between the bottom carrier film736 and a top surface of the first solar cell to provide additionalprotection at an edge of the first solar cell and to prevent shortingout the solar cell in the event that the bottom carrier film 736including the metallic layer should ride down the side of the firstsolar cell. The laminated-interconnect assembly 740 passes to theright-hand side of FIG. 7B and is taken up on the take-up spool 718 uponwhich it is wound as a fourth roll 742 of laminated-interconnectassembly 740. The arrows adjacent to the first unwinding spool 710, asecond unwinding spool 730 and the take-up spool 718 indicate that theseare rotating components of the roll-to-roll,laminated-interconnect-assembly fabricator 700B; the first unwindingspool 710, and the take-up spool 718 are shown rotating in clockwisedirection, as indicated by the arrow-heads on the respective arrowsadjacent to these components, to transport the unrolled portion of thefirst roll of material 714 from the first unwinding spool 710 on theleft to the take-up spool 718 on the right. The second unwinding spool730, and the dispenser 754 are shown rotating in a counterclockwisedirection and a clockwise direction, respectively, as indicated by thearrow-heads on the respective arrows adjacent to these components, asthey release the bottom carrier layer 736 and the conductive-tracematerial 750, respectively, in fabrication of the laminated-interconnectassembly 740. The double-headed arrow 758 indicates the motion impartedto the conductive trace material by the roll-to-roll,laminated-interconnect-assembly fabricator 700B creates a firstplurality of electrically conductive portions configured both to collectcurrent from a first solar cell and to interconnect electrically to asecond solar cell such that solar-cell efficiency is substantiallyundiminished in an event that any one of the first plurality ofelectrically conductive portions is conductively impaired.

Sub-Section B: Description of Embodiments of the Present Invention for aMethod for Roll-to-Roll Fabrication of an Interconnect Assembly

With reference now to FIG. 8, a flow chart illustrates an embodiment ofthe present invention for a method for roll-to-roll fabrication of aninterconnect assembly. At 810, a first carrier film including a firstsubstantially transparent, electrically insulating layer is provided inroll form. At 820, a trace is provided from a dispenser ofconductive-trace material. The dispenser may be a spool of wire or othercontainer of conductive-trace material. At 830, a portion of the firstcarrier film including the first substantially transparent, electricallyinsulating layer is unrolled. At 840, the trace from the dispenser ofconductive-trace material is laid down onto the portion of the firstcarrier film including the first substantially transparent, electricallyinsulating layer. At 850, the trace is configured as a first pluralityof electrically conductive portions such that solar-cell efficiency issubstantially undiminished in an event that any one of the firstplurality of electrically conductive portions is conductively impaired.At 860, the portion of the first the first carrier film including thesubstantially transparent, electrically insulating layer is coupled to atop portion of the trace to provide an interconnect assembly.

In an embodiment of the present invention, configuring the trace alsoincludes: configuring the trace as a second plurality of paired traceportions; configuring a first portion of a paired portion of the secondplurality of paired trace portions to allow both collecting current froma first solar cell and electrically interconnecting the first solar cellwith a second solar cell; disposing proximately to the first portion, asecond portion of the paired portion; and configuring the second portionto allow both collecting current from the first solar cell andelectrically interconnecting the first solar cell with the second solarcell. Alternatively, configuring the trace may include disposing thetrace in a serpentine pattern that allows for collecting current fromthe first solar cell and electrically interconnecting to the secondsolar cell. In an embodiment of the present invention, the method mayalso include: providing a second carrier film including a secondelectrically insulating layer; coupling the second carrier filmincluding the second electrically insulating layer to a bottom portionof the trace; and configuring the second electrically insulating layerto allow forming an edge-protecting portion at an edge of the firstsolar cell. Moreover, the method may include configuring the firstsubstantially transparent, electrically insulating layer to allowforming a short-circuit-preventing portion at an edge of the secondsolar cell.

Sub-Section C: Description of Embodiments of the Present Invention for aMethod of Interconnect Two Solar Cells

With reference now to FIG. 9, a flow chart illustrates an embodiment ofthe present invention for a method of interconnecting two solar cells.At 910, a first solar cell and at least a second solar cell areprovided. At 920, a combined applicable carrier film, interconnectassembly including a trace including a plurality of electricallyconductive portions is provided. At 930, the plurality of electricallyconductive portions of the trace is configured both to collect currentfrom the first solar cell and to interconnect electrically with thesecond solar cell such that solar-cell efficiency is substantiallyundiminished in an event that any one of the plurality of electricallyconductive portions is conductively impaired. At 940, the combinedapplicable carrier film, interconnect assembly is applied and coupled toa light-facing side of the first solar cell. At 950, the combinedapplicable carrier film, interconnect assembly is applied and coupled toa back side of the second solar cell.

In an embodiment of the present invention, the method also includesapplying and coupling the combined applicable carrier film, interconnectassembly to the light-facing side of the first solar cell withoutrequiring solder. In addition, the method may include applying andcoupling the combined applicable carrier film, interconnect assembly tothe back side of the second solar cell without requiring solder.Moreover, the method includes applying and coupling the combinedapplicable carrier film, interconnect assembly to the light-facing sideof the first solar cell such that a second electrically insulating layerof the applicable carrier film, interconnect assembly forms anedge-protecting portion at an edge of the first solar cell. The methodalso includes applying and coupling the combined applicable carrierfilm, interconnect assembly to the back side of the second solar cellsuch that a first substantially transparent, electrically insulatinglayer of the applicable carrier film, interconnect assembly forms ashort-circuit-preventing portion at an edge of the second solar cell.The method may also include configuring the trace in a serpentinepattern that allows for collecting current from the first solar cell andelectrically interconnecting to the second solar cell.

Sub-Section D: Physical Description of Embodiments of the PresentInvention for a Trace

In accordance with other embodiments of the present invention, the tracedoes not need to be used in conjunction with the afore-mentionedserpentine interconnect assembly approach, but could be used for othercurrent collection and/or interconnection approaches used in solar celltechnology. A trace including a conductive core with an overlying layerof nickel provides the unexpected result that when placed in contactwith the TCO layer of a solar cell it suppresses current in the vicinityof short-circuit defects in the solar cell that might occur in thevicinity of the contact of the nickel layer of the trace with the TCOlayer. The nickel increases local contact resistance which improves theability of the solar cell to survive in the event of the formation of adefect, such as a shunt or a near shunt, located in the adjacentvicinity of the contact of the nickel layer of the trace with the TCOlayer. If there is such a defect in the vicinity of the contact of thenickel layer of the trace with the TCO layer, the nickel reduces thetendency of the solar cell to pass increased current through the site ofthe defect, such as a shunt or a near shunt. Thus, the nickel acts as alocalized resistor preventing run-away currents and high currentdensities in the small localized area associated with the site of thedefect, such as a shunt or a near shunt. The current-limiting ability ofnickel is in contrast, for example, to a low resistivity material suchas silver, where the current density becomes so high at the location ofthe defect due to the high conductivity of silver that nearly almost allthe current of the cell would be passed at the location of the defectcausing a hot spot that would result in the melting of the silver withthe formation of a hole in the solar cell filling with the silvermigrating to the site of the defect to form a super-shunt. In contrast,nickel does not readily migrate nor melt in the presence of elevatedlocalized temperatures associated with the site of increased currentsattending formation of the defect, such as a shunt or a near shunt.Moreover, in contrast to silver, copper and tin, which tend toelectromigrate, migrate or diffuse at elevated temperatures, nickeltends to stay put so that if the site of a shunt occurs in the vicinityof a nickel coated or nickel trace, the nickel has less tendency to moveto the location of the shunt thereby further exacerbating the drop ofresistance at the shunt site. In addition, experimental results of thepresent invention indicate that a nickel trace, or a trace including anickel layer, may actually increase its resistance due the possibleformation of a nickel oxide such that the nickel trace, or the traceincluding the nickel layer, acts like a localized fuse limiting thecurrent flow in the vicinity of the shunt site. In some cases, theefficiency of the solar cell has actually been observed to increaseafter formation of the shunt defect when the nickel trace, or the traceincluding the nickel layer, is used in contact with the TCO layer.

With further reference to FIG. 5B and 5C, in accordance with otherembodiments of the present invention, the trace 520 for collectingcurrent from a solar cell, for example, first solar cell 510, includesan electrically conductive line including the conductive core 520A, andthe overlying layer 520B that limits current flow to a proximate shuntdefect (not shown) in the solar cell, for example, first solar cell 510.The proximate shunt defect may be proximately located in the vicinity ofan electrical contact between the overlying layer 520B of theelectrically conductive line and the TCO layer 510 b of the solar cell,for example, first solar cell 510. The overlying layer 520B of theelectrically conductive line of the trace 520 may further include anoverlying layer 520B composed of nickel. The conductive core 520A of theelectrically conductive line of the trace 520 may further includenickel. The conductive core 520A may also include a material selectedfrom a group consisting of copper, silver, aluminum, and elementalconstituents and alloys having high electrical conductivity, which maybe greater than the electrical conductivity of nickel. The TCO layer 510b of the solar cell, for example, first solar cell 510, may include aconductive oxide selected from a group consisting of zinc oxide,aluminum zinc oxide and indium tin oxide. In addition, the absorberlayer 510 a, for example, absorber layer 112 of FIG. 1A, of the solarcell, for example, first solar cell 510, may include copper indiumgallium diselenide (CIGS). Alternatively, in embodiments of the presentinvention, it should be noted that semiconductors, such as silicon,cadmium telluride, and chalcopyrite semiconductors, as well as othersemiconductors, may be used as the absorber layer 510 a. Moreover, ann-type layer, for example, n-type portion 112 b of absorber layer 112 ofFIG. 1A, of the solar cell, for example, first solar cell 510, may bedisposed on and electrically coupled to a p-type absorber layer, forexample, absorber layer 112 of FIG. 1A, of the solar cell, for example,first solar cell 510, and the n-type layer, for example, n-type portion112 b of absorber layer 112 of FIG. 1A, may be selected from a groupconsisting of a metal oxide, a metal sulfide and a metal selenide.

Section II: Physical Description of Embodiments of the Present Inventionfor a Solar-Cell Module Combined with In-Laminate Diodes andExternal-Connection Mechanisms Mounted to Respective Edge Regions

With reference now to FIG. 10, in accordance with embodiments of thepresent invention, a plan view 1000 is shown of a solar-cell module 1002combined with external-connection mechanisms (not shown) mounted torespective edge regions and in-laminate-diode assembly 1050. FIG. 10shows the physical arrangement of the solar-cell module 1002 combinedwith in-laminate-diode assembly 1050 and external-connection mechanismsmounted to respective edge regions, which may be located at edges 1090,1092, 1094 and 1096, or at corners 1080, 1082, 1084 and 1086. Thesolar-cell module 1002 includes a plurality 1010 of solar cellselectrically coupled together, for example, solar cells 1012 a-1017 aand 1012 b-1017 b, which may be disposed in at least one solar-cellsub-module, for example, solar-cell sub-modules 1010 a and 1010 b,respectively. (Throughout the following, solar cells: 1012 a, 1013 a,1014 a, 1015 a, 1016 a and 1017 a; 1012 b, 1013 b, 1014 b, 1015 b, 1016b and 1017 b; 1022 a, 1023 a, 1024 a, 1025 a, 1026 a and 1027 a; 1022 b,1023 b, 1024 b, 1025 b, 1026 b and 1027 b; 1032 a, 1033 a, 1034 a, 1035a, 1036 a and 1037 a; and, 1032 b, 1033 b, 1034 b, 1035 b, 1036 b and1037 b; are referred to in aggregate as: 1012 a-1017 a, 1012 b-1017 b,1022 a-1027 a, 1022 b-1027 b, 1032 a-1037 a and 1032 b-1037 b,respectively. Solar-cell sub-modules: 1010 a and 1010 b, 1020 a and 1020b and 1030 a and 1030 b, are referred to as: 1010 a-1010 b, 1020 a-1020b and 1030 a-1030 b, respectively.) The plurality 1010 of solar cells1012 a-1017 a and 1012 b-1017 b; is electrically interconnected with oneanother through interconnect assemblies (not shown) similar to thosediscussed in Section I in FIGS. 4A through 4F. The solar-cell module1002 also includes the in-laminate-diode assembly 1050 electricallycoupled with the plurality 1010 of solar cells 1012 a-1017 a and 1012b-1017 b. The in-laminate-diode assembly 1050 is configured to preventpower loss in the solar-cell module 1002, which can result, from amongstother causes, from shading of a particular solar cell, for example,solar cell 1012 a. In addition, the solar-cell module 1002 includes aprotective structure (not shown in FIG. 10, but in FIG. 14) at leastpartially encapsulating the plurality 1010 of solar cells 1012 a-1017 aand 1012 b-1017 b. As shown in FIG. 14, the protective structure mayinclude a front glass 1410, which is disposed over a light-facing sideof the solar cells 1012 a-1017 a and 1012 b-1017 b, and a back glass1414 that encapsulate the plurality 1010 of solar cells 1012 a-1017 aand 1012 b-1017 b. The solar-cell module 1002 also includes a pluralityof external-connection mechanisms mounted to a respective plurality ofedge regions of the protective structure. An external-connectionmechanism of the plurality of external-connection mechanisms isconfigured to enable collection of current from the plurality 1010 ofsolar cells 1012 a-1017 a and 1012 b-1017 b and to allow interconnectionwith at least one other external device (not shown). The external devicemay be selected from the group consisting of a solar-cell module, aninverter, a battery charger, an external load, and anelectrical-power-distribution system.

With further reference to FIG. 10, in accordance with embodiments of thepresent invention, it should be noted that: a photovoltaic-convertormeans for converting radiant power into electrical power may be a solarcell; a photovoltaic-convertor module may be a solar-cell module; aphotovoltaic-convertor sub-module may be a solar-cell sub-module; ancurrent-shunting means for by-passing current flow may be a diode; anin-laminate, current-shunting assembly means for by-passing current flowmay be an in-laminate-diode assembly; an in-laminate, current-shuntingsub-assembly means for by-passing current flow may be anin-laminate-diode sub-assembly; and a junction-enclosure means forprotecting and electrically isolating electrical connections may be anexternal-connection mechanism. Moreover, it should be noted that aphotovoltaic-convertor array may be a solar-cell array. With thepreceding identifications of terms of art, it should be noted thatembodiments of the present invention recited herein with respect to asolar cell, a solar-cell module, a solar-cell sub-module, a diode, anin-laminate-diode assembly, an in-laminate-diode sub-assembly, and anexternal-connection mechanism apply to a photovoltaic-convertor meansfor converting radiant power into electrical power, aphotovoltaic-convertor module, a photovoltaic-convertor sub-module, anin-laminate, current-shunting means for by-passing current flow, anin-laminate, current-shunting assembly means for by-passing currentflow, an in-laminate, current-shunting sub-assembly means for by-passingcurrent flow, and a junction-enclosure means for protecting andelectrically isolating electrical connections, respectively. Therefore,it should be noted that the preceding identifications of terms of art donot preclude, nor limit embodiments described herein, which are withinthe spirit and scope of embodiments of the present invention.

With further reference to FIG. 10, in accordance with embodiments of thepresent invention, the solar-cell module 1002, identified withsolar-cell module 1260 b, may be a component of a solar-cell array, forexample, solar-cell array 1252 as shown in FIG. 12B. Embodiments of thepresent invention also encompass the solar-cell array 1252, oralternatively a photovoltaic-convertor array, that may include aplurality of electrically coupled solar-cell modules, for example,solar-cell modules 1260 a, 1260 b and 1260 c. The solar-cell module, forexample, solar-cell modules 1260 b, of a plurality 1260 of electricallycoupled solar-cell modules 1260 a, 1260 b and 1260 c may include aplurality of solar cells, at least one solar-cell sub-module, anin-laminate-diode assembly, a protective structure and a plurality ofexternal-connection mechanisms as for embodiments of the presentinvention described herein.

With further reference to FIG. 10, in accordance with embodiments of thepresent invention, the in-laminate-diode assembly 1050 may include atleast one in-laminate-diode sub-assembly 1050 a, for example, from aplurality of in-laminate-diode sub-assemblies 1050 a-1050 b withoutlimitation thereto. As shown in FIG. 10, the in-laminate-diodesub-assemblies 1050 a-1050 b are electrically coupled in parallel withthe plurality 1010 of solar cells 1012 a-1017 a and 1012 b-1017 b, whichmay be disposed in solar-cell sub-modules, for example, solar-cellsub-modules 1010 a and 1010 b, respectively, as shown. (Throughout thefollowing, in-laminate-diode sub-assemblies: 1050 a and 1050 b, 1060 aand 1060 b and 1070 a and 1070 b, are referred to as: 1050 a-1050 b,1060 a-1060 b and 1070 a-1070 b, respectively.) At least onein-laminate-diode sub-assembly, for example, in-laminate-diodesub-assembly 1050 a, includes at least one diode (not shown) and isconfigured to by-pass current flow around the solar-cell sub-module, forexample, solar-cell sub-module 1010 a, in an event at least one solarcell, for example, solar cell 1012 a, of the plurality of solar cells1012 a-1017 a develops high resistance to passage of solar-cell-modulecurrent, as may occur in case of shading of a solar-cell. As usedherein, an in-laminate diode is a diode included in an in-laminate diodeassembly or in-laminate-diode sub-assembly, where the term of art“in-laminate” refers to the disposition of the diode within such anassembly or sub-assembly rather than any inherent functionality of thediode itself. In addition, the solar-cell module 1002 may include aplurality of external-connection mechanisms mounted to respective edgeregions, for example, external-connection mechanisms 1280 b and 1282 bmounted to respective edge regions, for example, corners as shown inFIG. 12B. At least one external-connection mechanism 1282 b mounted torespective edge regions of the plurality of external-connectionmechanisms 1280 b and 1282 b may be disposed at a cut corner of a backglass of the solar-cell module, for example, the solar-cell module 1260b. The external-connection mechanism 1280 b and 1282 b mounted torespective edge regions of the plurality of external-connectionmechanisms 280 b and 1282 b are configured to collect current from thesolar-cell module 1260 b and to allow interconnection with at least oneother external device, for example, the solar-cell module 1260 c.

With further reference to FIG. 10, in accordance with embodiments of thepresent invention, the solar-cell module 1002 may include a secondplurality 1020 of solar cells 1022 a-1027 a and 1022 b-1027 b. Thesecond plurality 1020 of solar cells 1022 a-1027 a and 1022 b-1027 b iselectrically interconnected with one another through interconnectassemblies (not shown) similar to those discussed in Section I in FIGS.4A through 4F. Solar cells may be electrically coupled together in atleast one solar-cell sub-module, for example, solar-cell sub-module 1020a may include solar cells 1022 a-1027 a, and solar-cell sub-module 1020b may include solar cells 1022 b-1027 b. The solar-cell module 1002 mayalso include a second in-laminate-diode assembly 1060 including a secondplurality of in-laminate-diode sub-assemblies 1060 a-1060 b such thatthe in-laminate-diode sub-assemblies 1060 a-1060 b are electricallycoupled in parallel with the second plurality 1020 of solar cells 1022a-1027 a and 1022 b-1027 b, and which may be electrically coupled inparallel with solar-cell sub-modules 1020 a-1020 b. At least onein-laminate-diode sub-assembly, for example, in-laminate-diodesub-assembly 1060 a, includes at least one diode (not shown) and isconfigured to by-pass current flow around the solar-cell sub-module, forexample, solar-cell sub-module 1020 a, in an event at least one solarcell, for example, solar cell 1022 a, of the plurality 1020 of solarcells including solar cells 1022 a-1027 a develops high resistance topassage of solar-cell-module current. As shown in FIG. 10, thein-laminate-diode sub-assembly 1060 a is also shown with some of itscomponent conductors removed to reveal disposition of a portion of anelectrically-insulating-laminate strip with respect to the secondin-laminate-diode assembly 1060 and a portion of the second plurality1020 of solar cells 1022 a-1025 a, which will be discussed below ingreater detail in the description of FIG. 13.

With further reference to FIG. 10, in accordance with embodiments of thepresent invention, the solar-cell module 1002 may include a thirdplurality 1030 of solar cells 1032 a-1037 a and 1032 b-1037 b. The thirdplurality 1030 of solar cells 1032 a-1037 a and 1032 b-1037 b iselectrically interconnected with one another through interconnectassemblies (not shown) similar to those discussed in Section I in FIGS.4A through 4F. Solar cells may be electrically coupled together in atleast one solar-cell sub-module, for example, solar-cell sub-module 1030a may include solar cells 1032 a-1037 a, and solar-cell sub-module 1030b may include solar cells 1032 b-1037 b. The solar-cell module 1002 mayalso include a third in-laminate-diode assembly 1070 including a thirdplurality of in-laminate-diode sub-assemblies 1070 a-1070 b such thatthe in-laminate-diode sub-assemblies 1070 a-1070 b are electricallycoupled in parallel with the third plurality 1030 of solar cells 1032a-1037 a and 1032 b-1037 b, and which may be electrically coupled inparallel with solar-cell sub-modules 1030 a-1030 b. At least onein-laminate-diode sub-assembly, for example, in-laminate-diodesub-assembly 1070 a, includes at least one diode (not shown) and isconfigured to by-pass current flow around the solar-cell sub-module, forexample, solar-cell sub-module 1030 a, in an event at least one solarcell, for example, solar cell 1032 a, of the third plurality 1030 ofsolar cells including solar cells 1032 a-1037 a develops high resistanceto passage of solar-cell-module current. As shown in FIG. 10, thein-laminate-diode sub-assemblies 1070 a and 1070 b are also shown withsome of their component conductors removed to reveal disposition ofrespective electrically-insulating-laminate strips with respect to thethird in-laminate-diode assembly 1070 and a portion of the thirdplurality 1030 of solar cells 1032 a-1037 a and 1032 b-1034 b, whichwill also be discussed below in greater detail in the description ofFIG. 13.

With further reference to FIG. 10, in accordance with embodiments of thepresent invention, a solar-cell sub-module 1010 a includes at least onesolar cell 1012 a. Alternatively, the solar-cell sub-module 1010 a mayinclude a plurality of solar cells 1012 a-1017 a, as shown. A portion1012 a-1017 a of the plurality 1010 of solar cells 1012 a-1017 a and1012 b-1017 b of the solar-cell sub-module 1010 a is electricallycoupled in series. The in-laminate-diode assembly 1050 includes aplurality of in-laminate-diode sub-assemblies 1050 a-1050 b. At leastone in-laminate-diode sub-assembly 1050 a includes at least one diode(not shown) is configured to by-pass current flow around the solar-cellsub-module 1010 a to prevent power loss in the solar-cell module 1002.The in-laminate-diode sub-assembly 1050 a is configured to by-passcurrent flow around the solar-cell sub-module 1010 a such that the diode(not shown) of the in-laminate-diode assembly 1050 a is electricallycoupled in parallel with the solar-cell sub-module 1010 a with reversepolarity to polarities of the portion 1012 a-1017 a of the plurality1010 of solar cells 1012 a-1017 a and 1012 b-1017 b of the solar-cellsub-module 1010 a. The plurality of solar-cell sub-modules 1010 a-1010 bis electrically coupled in series. In addition, the plurality ofin-laminate-diode sub-assemblies 1050 a-1050 b is electrically coupledin series.

With reference now to FIGS. 11A-11D, several embodiments of the presentinvention are shown that illustrate the manner in which a diode may beelectrically coupled with at least one or a plurality of solar cells.Within the spirit and scope of embodiments of the present invention, atleast one or the plurality of solar cells may be disposed in thesolar-cell sub-module, and the diode may be disposed in anin-laminate-diode sub-assembly of an in-laminate diode assembly. FIG. 11A shows a schematic diagram 1100A of a diode 1110 used to by-passcurrent around a solar cell 1120 and electrically coupled in parallelwith one solar cell 1120. The diode 1110 is electrically coupled inparallel to the solar cell 1120 at a first terminal 1132 and at a secondterminal 1130. To by-pass current around the solar cell 1120 in an eventthat the solar cell 1120 develops a high resistance to the passage ofsolar-cell module current, the diode 1110 is coupled to solar cell 1120with reverse polarity to that of the solar cell 1120. FIG. 11B shows aschematic diagram 100B of the diode 1110 used to by-pass current arounda plurality of solar cells and electrically coupled in parallel with theplurality of solar cells that are electrically coupled in parallel. Thediode 1110 is electrically coupled in parallel to the combination ofsolar cell 1120 and a parallel solar cell 1122. The diode 1110 iselectrically coupled with the parallel combination of solar cells 1120and 1122 at first terminal 1132 and at second terminal 1130. To by-passcurrent around the parallel combination of solar cells 1120 and 1122 inan event that at least one of the solar cells 1120 or 1122 develops ahigh resistance to the passage of solar-cell module current, the diode1110 is coupled to the solar cells 1120 and 1122 with reverse polarityto both of the solar cells 1120 and 1122. FIG. 11C shows a schematicdiagram 1100C of the diode 1110 used to by-pass current around aplurality of solar cells and electrically coupled in parallel with theplurality of solar cells 1120 and 1124 that are electrically coupled inseries. The diode 1110 is electrically coupled in parallel to thecombination of solar cell 1120 and solar cell 1124 coupled in serieswith solar cell 1120. The diode 1110 is electrically coupled with theseries combination of solar cells 1120 and 1124 at first terminal 1132and at second terminal 1130. To by-pass current around the seriescombination of solar cells 1120 and 1124 in an event that at least oneof the solar cells 1120 or 1124 develops a high resistance to thepassage of solar-cell module current, the diode 1110 is coupled to thesolar cells 1120 and 1122 with reverse polarity to both of the solarcells 1120 and 1124. FIG. 11D shows a schematic diagram 1100D of a diodeused to by-pass current around a plurality of solar cells andelectrically coupled in parallel with the plurality of solar cells thatare electrically coupled in series and in parallel. The diode 1110 iselectrically coupled in parallel to the combination of solar cell 1120and solar cell 1124 coupled in series with solar cell 1120 and thecombination of solar cell 1122 and solar cell 1126 coupled in serieswith solar cell 1122. The diode 1110 is electrically coupled with theseries/parallel combination of solar cells 1120, 1124, 1122 and 1126 atfirst terminal 1132 and at second terminal 1130. To by-pass currentaround the series/parallel combination of solar cells 1120, 1124, 1122and 1126 in an event that at least one of the solar cells 1120, 1124,1122 and 1126 develops a high resistance to the passage of solar-cellmodule current, the diode 1110 is coupled to the solar cells 1120, 1124,1122 and 1126 with reverse polarity to the solar cells 1120, 1124, 1122and 1126. In accordance with embodiments of the present invention, asolar-cell sub-module may be selected from the group consisting of onesolar cell, a parallel combination of solar cells, a series combinationof solar cells and a series/parallel combination of solar cells.Moreover, although embodiments of the present invention have been shownas just two solar cells electrically coupled in series, and just twoparallel legs of a circuit of solar cells electrically coupled inparallel, embodiments of the present invention include pluralities ofseries coupled solar cells greater than two, and pluralities of parallelcoupled solar cells or parallel coupled pluralities of series coupledsolar cells greater than two. Therefore, embodiments of the presentinvention include a diode electrically coupled in parallel with anynetwork that includes a configuration of interconnected solar cells, inwhich the diode serves to by-pass current around the network in an eventthe network, or alternatively a solar cell within the network, developshigh resistance to the flow of current through the solar-cell module.

With further reference to FIG. 10, in accordance with embodiments of thepresent invention, the solar-cell module 1002 includes at least one pairof first and terminating busbars 1019 a and 1019 b, respectively,electrically coupled to a first end and a terminating end of theplurality 1010 of solar-cells 1012 a-1017 a and 1012 b-1017 b. The firstbusbar 1019 a may be disposed on and electrically coupled to a back sideof a first solar cell, for example, solar cell 1012 a. The terminatingbusbar 1019 b may be disposed proximately to and electrically coupled toa light-facing side of a terminating solar cell 1017 b. The pair offirst and terminating busbars, respectively, 1019 a and 1019 b iselectrically coupled to the pair of external-connection mechanismsmounted to respective edge regions, respectively, for example, locatedat corners 1080 and 1082. Alternatively, the solar-cell module 1002 mayalso include other pairs of first and terminating busbars (not shown),which may be electrically coupled to a first end and a terminating endof the second plurality 1020 of solar-cells 1022 a-1027 a and 1022b-1027 b, or the third plurality 1030 of solar-cells 1032 a-1037 a and1032 b-1037 b. Other first busbars may be disposed on and electricallycoupled to back sides of respective first solar cells 1022 a and 1032 a.Other terminating busbars may be disposed proximately to andelectrically coupled to light-facing sides of respective terminatingsolar cells 1027 b and 1037 b. The other pairs of first and terminatingbusbars may also be electrically coupled to the pair ofexternal-connection mechanisms mounted to respective edge regions,respectively, for example, located at corners 1080 and 1082. The firstbusbar 1019 a and the other first busbars may be separate entities thatmay be separated by one or more gaps; and, the terminating busbar 1019 band the other terminating busbars may be separate entities that may beseparated by a second set of one or more gaps. In an embodiment of thepresent invention, the first busbar 1019 a may be electrically coupledtogether with the other first busbars and the terminating busbar 1019 bmay be electrically coupled together with the other terminating busbarssuch that pluralities 1010, 1020 and 1030 of solar cells areelectrically coupled in parallel. However, as shown in FIG. 10, thereare no other busbars besides first busbar and terminating busbars 1019 aand 1019 b; only a single first busbar 1019 a and a single terminatingbusbars 1019 b electrically couple the pluralities 1010, 1020 and 1030of solar cells in parallel.

With further reference to FIG. 10, in accordance with embodiments of thepresent invention, the solar-cell module 1002 may further include anintegrated busbar-solar-cell-current collector as described above inSection I and shown in FIGS. 6A and 6B. The integratedbusbar-solar-cell-current collector 690 includes the terminating busbar680, identified with the terminating busbar 1019 b of solar-cell module1002, and the integrated solar-cell, current collector 670. Theintegrated solar-cell, current collector 670 includes the plurality ofintegrated pairs 670 a&b, 670 c&d, 670 e&f, 670 g&h, and 670 l&m and 670i of electrically conductive, electrically parallel trace portions 670a-m. The plurality of integrated pairs 670 a&b, 670 c&c, 670 e&f, 670g&h, 670 i and 670 l&m of electrically conductive, electrically paralleltrace portions 670 a-m is configured both to collect current from theterminating solar cell 660, identified with solar cell 1017 b, and tointerconnect electrically to the terminating busbar 680. The pluralityof integrated pairs 670 a&b, 670 c&c, 670 e&f, 670 g&h, 670 i and 6701&mof electrically conductive, electrically parallel trace portions 670 a-mis configured such that solar-cell efficiency is substantiallyundiminished in an event that any one electrically conductive,electrically parallel trace portion, for example, 670 h, of theplurality of integrated pairs 670 a&b, 670 c&c, 670 e&f, 670 g&h, 670 iand 6701&m of electrically conductive, electrically parallel traceportions 670 a-m is conductively impaired. The terminating busbar 680may be disposed above, or below, and coupled electrically to extendedportions, for example, extended portions 670 x and 670 y, of theplurality of integrated pairs 670 a&b, 670 c&c, 670 e&f, 670 g&h, 670 iand 670 l&m of electrically conductive, electrically parallel traceportions 670 a-m configured such that the terminating busbar 680 isconfigured to reduce shadowing of the terminating solar cell 660. Theextended portions 670 x and 670 y of the plurality of integrated pairsof electrically conductive, electrically parallel trace portions 670a&b, 670 c&c, 670 e&f, 670 g&h, 670 i and 670 l&m allow the terminatingbusbar 680 to fold under the back side 668 of the terminating solar cell660, identified with the terminating solar cell 1017 b of solar-cellmodule 1002. Therefore, in accordance with embodiments of the presentinvention, the terminating busbar 680, identified with the terminatingbusbar 1019 b of solar-cell module 1002, may be folded under the backside 668 of the terminating solar cell 660, identified with theterminating solar cell 1017 b of solar-cell module 1002. Consequently,but without limitation to the folded-under configuration for theterminating busbar 680 described above, the solar-cell module 1002 maybe arranged with a configuration to minimize wasted solar-collectionspace within the solar-cell module 1002 such that solar-cell-moduleefficiency is greater than solar-cell-module efficiency in the absenceof such configuration, in accordance with embodiments of the presentinvention.

With further reference to FIG. 10, in accordance with embodiments of thepresent invention, the solar-cell module 1002 may further include aninterconnect assembly 420 as described above in Section I and shown inFIGS. 4B and 4C. The solar-cell module 404, identified with solar-cellmodule 1002, includes the first solar cell 410, identified with solarcell 1012 a, at least the second solar cell 430, identified with solarcell 1013 a, and the interconnect assembly 420 disposed above thelight-facing side 416 of the absorber layer of the first solar cell 410.The interconnect assembly 420 includes the trace including the pluralityof electrically conductive portions 420 a, 420 b, 420 c, 420 i and 420m. The plurality of electrically conductive portions 420 a, 420 b, 420c, 420 i and 420 m is configured both to collect current from the firstsolar cell 410 and to interconnect electrically to the second solar cell430. The plurality of electrically conductive portions 420 a, 420 b, 420c, 420 i and 420 m is configured such that solar-cell efficiency issubstantially undiminished in an event that any one of the plurality ofelectrically conductive portions 420 a, 420 b, 420 c, 420 i and 420 m isconductively impaired. In accordance with embodiments of the presentinvention, the plurality of electrically conductive portions 420 a, 420b, 420 c, 420 i and 420 m of the interconnect assembly 420 may becoupled electrically in series to form a single continuous electricallyconductive line. In addition, the trace of the interconnect assembly 420may be disposed in a serpentine pattern such that the interconnectassembly 420 is configured to collect current from the first solar cell410 and to interconnect electrically to the second solar cell 430.

With further reference to FIG. 10, in accordance with embodiments of thepresent invention, the trace of the interconnect assembly 420interconnecting the solar cells 1012 a and 1013 a of the solar-cellmodule 1002 is further described above in Section I and shown in FIGS.5B and 5C. The trace 520 may further include an electrically conductiveline including a conductive core 520A and at least one overlying layer520B overlying the conductive core 520A. Alternatively, the trace 520may include the electrically conductive line including the conductivecore 520A including nickel, without the overlying layer 520B; or, thetrace 520 may include the electrically conductive line including theconductive core 520A including material having greater conductivity thannickel and the overlying layer 520B including nickel.

With reference now to FIG. 12B, in accordance with embodiments of thepresent invention, a plan view 1200B of the solar-cell array 1252including the plurality 1260 of solar-cell modules 1260 a, 1260 b and1260 c is shown. FIG. 12B shows the plurality 1260 of solar-cell modules1260 a, 1260 b and 1260 c combined with external-connection mechanismsmounted to respective edge regions and in-laminate-diode assemblies. Forexample, solar-cell module 1260 b includes a first in-laminate-diodeassembly 1270, a second in-laminate-diode assembly 1271 and a thirdin-laminate-diode assembly 1272; solar-cell module 1260 b also includesa first busbar 1274 and a terminating busbar 1276 each electricallycoupled with the first, second and third in-laminate-diode assemblies1270, 1271 and 1272. The solar-cell module 1260 b further includes afirst external-connection mechanism 1280 b, for example, a firstjunction box, mounted to a first edge region, for example, a firstcorner, of the protective structure and a second external-connectionmechanism 1282 b, for example, a second junction box, mounted to asecond edge region, for example, a second corner, of the protectivestructure. The first external-connection mechanism 1280 b mounted to afirst respective edge region is configured to enable collection ofcurrent from the solar cells of the solar-cell module 1260 b and toallow interconnection with at least one other external device, as shownhere solar-cell module 1260 a. Similarly, the second external-connectionmechanism 1282 b mounted to a second respective edge region isconfigured to enable collection of current from the solar-cellsub-modules of the solar-cell module 1260 b and to allow interconnectionwith at least one other external device, as shown here solar-cell module1260 c. In embodiments of the present invention, the solar-cell module1260 b is coupled in series with the other solar-cell module 1260 a, andalso solar-cell module 1260 c. However, in accordance with embodimentsof the present invention, solar-cell modules may be interconnected inparallel or series/parallel combinations which are within the spirit andscope of the embodiments of the present invention.

With further reference to FIG. 12B, in accordance with embodiments ofthe present invention, solar-cell module 1260 a also includes firstexternal-connection mechanism 1280 a, for example, a first junction box,mounted to a first edge region, for example, a first corner, of theprotective structure of solar-cell module 1260 a and a secondexternal-connection mechanism 1282 a, for example, a second junctionbox, mounted to a second edge region, for example, a second corner, ofthe protective structure of solar-cell module 1260 a. Similarly,solar-cell module 1260 c also includes a first external-connectionmechanism 1280 c, for example, a first junction box, mounted to a firstedge region, for example, a first corner, of the protective structure ofsolar-cell module 1260 c and a second external-connection mechanism 1282c, for example, a second junction box, mounted to a second edge region,for example, a second corner, of the protective structure of solar-cellmodule 1260 c.

With further reference to FIG. 12B, in accordance with embodiments ofthe present invention, the external-connection mechanism 1280 b mountedto its respective edge region of solar-cell module 1260 b is disposed ina configuration opposite the external-connection mechanism 1282 bmounted to its respective edge region of solar-cell module 1260 b on alateral side of the solar-cell module 1260 b. This configuration, whenapplied to the plurality 1260 of all solar-cell modules 1260 a, 1260 band 1260 c, allows the two solar-cell modules 1260 a and 1260 b withexternal-connection mechanisms 1282 a and 1280 b mounted to respectiveedge regions to be disposed on respective lateral sides of the twosolar-cell modules 1260 a and 1260 b. The solar-cell modules 1260 a and1260 b, thus configured, may be intercoupled with interconnector 1284.Thus, the second external-connection mechanism 1282 a of the firstsolar-cell module 1260 a may be disposed proximately to the firstexternal-connection mechanism 1280 b of the second solar-cell module1260 b. Alternatively, the first external-connection mechanism 1280 c ofthe third solar-cell module 1260 c may be disposed proximately to thesecond the second external-connection mechanism 1282 b of the secondsolar-cell module 1260 b. Thus, in accordance with embodiments of thepresent invention, a first external-connection mechanism of a pluralityof external-connection mechanisms of a solar-cell module is disposedproximate to a second external-connection mechanism of a secondplurality of external-connection mechanisms of another solar-cellmodule. Moreover, in accordance with embodiments of the presentinvention, a first external-connection mechanism of a plurality ofexternal-connection mechanisms of a solar-cell module, for example, thefirst external-connection mechanism 1280 c of third solar-cell module1260 c, and a second external-connection mechanism of a plurality ofexternal-connection mechanisms of a second solar-cell module, forexample, the second external-connection mechanism 1282 b of solar-cellmodule 1260 b, are arranged on their respective solar-cell modules 1260c and 1260 b to minimize a length of an interconnector 1288 between thefirst external-connection mechanism 1280 c and the secondexternal-connection mechanism 1282 b. Thus, the solar-cell modules 1260a, 1260 b and 1260 c are intercoupled to form the solar-cell array 1252.Furthermore, in accordance with embodiments of the present invention, afirst external-connection mechanism of a plurality ofexternal-connection mechanisms of a solar-cell module may be selectedfrom the group consisting of a wire, a connector, a lead, and a junctionbox. Also, an edge region may be selected from the group consisting ofan edge of the solar-cell module and a corner of the solar-cell module,where two edges may meet.

With reference now to FIG. 12A, the embodiments of the present inventiondescribed for FIG. 12B are contrasted with another embodiment of thepresent invention that employs centrally-mounted junction boxes 1230 a,1230 b and 1230 c. FIG. 12A is a plan view 1200A of a solar-cell array1202 including a plurality 1210 of solar-cell modules 1210 a, 1210 b and1210 c combined with centrally-mounted junction boxes 1230 a, 1230 b and1230 c and in-laminate-diode assemblies 1220, 1212 and 1222 (shown onlyfor solar-cell module 1210 b). Solar-cell module 1210 b includes a firstin-laminate-diode assembly 1220, a second in-laminate-diode assembly1221 and a third in-laminate-diode assembly 1222. Solar-cell module 1210b also includes a first busbar 1224 and a terminating busbar 1226 eachelectrically coupled with the first, second and third in-laminate-diodeassemblies 1220, 1221 and 1222. Because the junction box 1230 b ofsolar-cell module 1210 b is centrally mounted, centrally-mountedjunction box 1230 b requires additional wiring to collect current fromthe solar-cell module 1210 b. For example, a first supplemental busbar1228 is electrically coupled to the first busbar 1224; and a secondsupplemental busbar 1229 is electrically coupled to the terminatingbusbar 1226. Similarly, because the junction box 1230 b of solar-cellmodule 1210 b is centrally mounted, long interconnectors are requiredbetween solar-cell modules. For example, a first interconnector 1234between centrally-mounted junction boxes 1230 a and 1230 b is requiredto interconnect solar-cell modules 1210 a and 1210 b; and, a secondinterconnector 1238 between centrally-mounted junction boxes 1230 b and1230 c is required to interconnect solar-cell modules 1210 b and 1210 c.As shown in FIG. 12A, the first interconnector 1234 includes twoportions 1234 a and 1234 b which attach respectively tocentrally-mounted junction boxes 1230 a and 1230 b, and are providedwith connectors joining the two portions together; and, the secondinterconnector 1238 includes two portions 1238 a and 1238 b which attachrespectively to centrally-mounted junction boxes 1230 b and 1230 c, andare provided with connectors joining the two portions together. Thisarrangement is contrasted with the short interconnectors 1284 and 1288shown in FIG. 12B. Thus, the interconnection arrangement shown in FIG.12B is less costly, because it requires less wiring, and improvessolar-cell array efficiency, because there is less parasitic seriesresistance than would obtain with the additional wiring shown in FIG.12A.

With further reference to FIGS. 12A and 12B, another distinguishingfeature of embodiments of the present invention of FIG. 12B is that theuse of an in-laminate-diode assembly facilitates the use of a pluralityof external-connection mechanisms mounted to a respective plurality ofedge regions. For embodiments of the present invention of FIG. 12Ahaving centrally mounted junction boxes, a single diode included in thejunction box would typically be employed instead of thein-laminate-diode assemblies, as shown. To the inventors' knowledge, oneof the reasons those skilled in the art have not considered usingseparate junction boxes is because of the difficulty in placing a diodewithin separated junction boxes to provide the by-pass protectiondiscussed above. Thus, a distinguishing feature of embodiments of thepresent invention is the use of an in-laminate-diode assembly thatallows the use of separate junction boxes without the necessity ofincluding diodes within a junction box.

With reference now to FIG. 13, in accordance with embodiments of thepresent invention, a combined perspective-plan and expanded view 1300 ofan in-laminate-diode sub-assembly 1302 with diode 1310 is shown at thetop and right of the figure. Also, towards the bottom and left of FIG.13, a perspective-plan view of a second in-laminate-diode sub-assembly1304 in a more fully assembled state is shown. The in-laminate-diodeassembly of a solar-cell module, for example, in-laminate-diode assembly1050 of solar-cell module 1002 of FIG. 10, may include a plurality ofin-laminate-diode sub-assemblies, for example, in-laminate-diodesub-assemblies 1050 a and 1050 b. Altrenatively, an in-laminate-diodeassembly may include at least one in-laminate-diode sub-assembly. Thein-laminate-diode sub-assembly 1302, which may be identified within-laminate-diode sub-assembly 1050 b, includes the diode 1310. Thein-laminate-diode sub-assembly also includes a first conductor 1320electrically coupled to the diode 1310. The first conductor 1320 isconfigured to couple electrically with a first terminal, which may beelectrically coupled to a back side, of a primary solar cell of thesolar-cell sub-module. The in-laminate-diode sub-assembly 1302 alsoincludes a second conductor 1330 electrically coupled to the diode 1310,the second conductor 1330 configured to couple electrically with asecond terminal, which may be electrically coupled to a light-facingside, of a last solar cell of the solar-cell sub-module.

With further reference to FIG. 13, in accordance with embodiments of thepresent invention, the diode 1310 is disposed between the firstconductor 1320 and the second conductor 1330. In the expanded view atthe top and right of FIG. 13, the disposition of the diode 1310 betweenfirst and second conductors 1320 and 1330 is indicated by adouble-headed arrow 1350. The diode 1310 is disposed between a first tabportion 1320 a of first conductor 1320 and a second tab portion 1330 aof second conductor 1330. In an embodiment of the present invention, thediode may be a simple chip diced from a silicon wafer having a pnjunction, as may be the case for an initially homogenously doped waferwith a diffused or implanted dopant profile of opposite type from adopant species used in growing a boule from which the wafer is sliced.At least one of the first and second conductors 1320 and 1330 may beconfigured as a heat sink to remove heat generated by the diode 1310,although a heat-dissipating function may be provided by separatecomponents. Because first and second conductors 1320 and 1330 may havethe dual function of both providing an electrical path for, anddissipating heat generated by, current that by-passes a solar-cellsub-module with high resistance, both first conductor 1320 and secondconductor 1330 may have a large current-carrying and heat-dissipatingportions 1320 b and 1330 b, respectively. Alternatively, thein-laminate-diode assembly may be made with separate components for theheat-spreading function and the current-carrying function. Therefore,the first and second conductors 1320 and 1330 may be configured toprovide an electrical path for current that by-passes a solar-cellsub-module; and, separate heat sinks configured as separate componentsfrom the first and second conductors 1320 and 1330 may be provided todissipate heat generated by current that by-passes a solar-cellsub-module. In addition, both first conductor 1320 and second conductor1330 may have broad low-contact-resistance portions 1320 c (not shownfor second conductor 1330) for making electrical contact andelectrically coupling with respective portions of solar cells, or othercomponents, for example, busbars, in the solar-cell sub-module, whichthe in-laminate-diode sub-assembly protects. In addition, thein-laminate-diode sub-assembly 1302 includes anelectrically-insulating-laminate strip 1340. Theelectrically-insulating-laminate strip 1340 may be disposed between aplurality of first and second terminals, which may be back sides, ofsolar cells of the solar-cell sub-module, and the first conductor 1320and the second conductor 1330. In an embodiment of the presentinvention, the plurality of first and second terminals of solar cellsmay be exclusive of the back side of the primary, or first, solar cellof a solar-cell sub-module.

With further reference to FIG. 13, in accordance with embodiments of thepresent invention, the back side of a solar cell may provide electricalcoupling to both the light-facing side of one solar cell in thesolar-cell sub-module and the back side of an adjacent solar cell in anadjacent solar-cell sub-module as for the interconnect assemblydescribed above for FIGS. 4A-4F. The first terminal may be electricallycoupled to a positive terminal or a negative terminal of a solar cell inthe solar-cell sub-module with which the diode is electrically coupledin parallel as described above for FIGS. 11A-11D. Similarly, the secondterminal may be electrically coupled to a positive terminal or anegative terminal of a solar cell in the solar-cell sub-module withwhich the diode is electrically coupled in parallel, but the secondterminal will be electrically coupled to the terminal of the solar cellhaving opposite polarity to that of the terminal of the solar cell towhich the first terminal is electrically coupled. For example, if thefirst terminal is electrically coupled to a positive terminal of a solarcell, the second terminal will be electrically coupled to a negativeterminal of a solar cell. However, the polarity of the diode will alwaysbe electrically coupled with opposite to the polarity of the solar cellterminals with which the first and second terminals are electricallycoupled as described above for FIGS. 11A-11D. In an embodiment of thepresent invention, the back side of a solar cell corresponds to positiveterminal of the solar cell, and the light-facing side corresponds tonegative terminal of the solar cell, as for the CIGS solar cellsdescribed in FIGS. 1A-1B. However, it should be noted that nothingprecludes the application of embodiments of the present invention tosolar-cell modules where the back side of a solar cell corresponds to anegative terminal of the solar cell, and the light-facing sidecorresponds to a positive terminal of the solar cell, or alternativelywhere both the positive and negative terminals of the solar cell may bedisposed on the same side of the solar cell, whether it may be a backside or a light-facing side, so that such embodiments of the presentinvention are within the spirit and scope of embodiments of the presentinvention.

With further reference to FIG. 13, in accordance with embodiments of thepresent invention, the in-laminate-diode sub-assembly 1302 furtherincludes the electrically-insulating-laminate strip 1340 configured toallow access of at least one of the first and second conductors 1320 and1330 to a solar cell of the plurality of solar cells of a solar-cellmodule, or solar-cell sub-module, for electrically coupling with thesolar cell. For example, the electrically-insulating-laminate strip 1340may include a continuous electrically-insulating-laminate strip with anaccess region 1342 through which the first conductor electricallycouples with the back side of the primary solar cell. Alternatively, theelectrically-insulating-laminate strip 1340 may include a plurality ofseparate electrically-insulating-laminate sub-strips separated by gapscorresponding with first and second terminals at which anin-laminate-diode sub-assembly makes contact with solar cells of thesolar-cell sub-module. Therefore, the access region 1342 may be selectedfrom the group consisting of a window, an opening, an aperture, a gap,and a discontinuity in the electrically-insulating-laminate strip 1340.As shown in FIG. 13, this also allows the second conductor 1330 toelectrically couple with the light-facing side of the last solar cell ofthe solar-cell sub-module, because the light-facing side of the lastsolar cell of the solar-cell sub-module may be electrically coupled incommon with the back side of the primary solar cell of an adjacentsolar-cell sub-module through an interconnect assembly between the backside of the primary solar cell and the light-facing side of the lastsolar cell of adjacent solar-cell sub-modules (not shown).

With further reference to FIG. 13, in accordance with embodiments of thepresent invention, the in-laminate-diode sub-assembly 1302 furtherincludes at least one of the first and second conductors 1320 and 1330structured to enable a laminated electrical connection between at leastone of the first and second conductors 1320 and 1330 and anothercomponent of the solar-cell module. Another component of the solar-cellmodule may be a first busbar, a terminating busbar and the terminal of asolar cell of a solar-cell sub-module. The laminated electricalconnection does not require solder, welding, a conducting adhesive orany other material disposed between a first contacting surface of thefirst conductor 1320 and/or second conductor 1330 and a secondcontacting surface of the other component of the solar-cell module towhich the first conductor 1320 and/or second conductor 1330 areelectrically connected. The laminated electrical connection requiresonly that a mechanical pressure be applied to hold the first conductor1320 and/or second conductor 1330 in intimate contact with the othercomponent of the solar-cell module to which the first conductor 1320and/or second conductor 1330 are electrically connected.

With further reference to FIG. 10 and FIG. 13, in accordance withembodiments of the present invention, the first conductor 1320 mayfurther include a first electrically-conducting-laminate stripconfigured to couple electrically with a first terminal of an adjacentlast solar cell, for example, solar cell 1017 a, of a first adjacentsolar-cell sub-module, for example, solar-cell sub-module 1010 a, andelectrically coupled with a first adjacent diode. In an embodiment ofthe present invention, the first terminal of the adjacent last solarcell of the first adjacent solar-cell sub-module may be a light-facingside of the adjacent last solar cell of the first adjacent solar-cellsub-module. Thus, the first electrically-conducting-laminate strip hasthe function of both the first conductor 1320 of in-laminate-diodesub-assembly 1302 and the second conductor of second in-laminate-diodesub-assembly 1304. As shown in FIG. 13, the first conductor 1320 ofin-laminate-diode sub-assembly 1302 has portions 1320 d, 1320 e and 1320f that serve, respectively, as a broad low-contact-resistance portion1320 d, a large current-carrying and heat-dissipating portion 1320 e anda second tab portion 1320 f as a second conductor of secondin-laminate-diode sub-assembly 1304. Alternatively, the second conductorof second in-laminate-diode sub-assembly 1304 may be separated from thefirst conductor 1320 of in-laminate-diode sub-assembly 1302 along dashedline 1352 to provide the functions of the broad low-contact-resistanceportion 1320 d, the large current-carrying and heat-dissipating portion1320 e and the second tab portion 1320 f of the second conductor ofsecond in-laminate-diode sub-assembly 1304. Similarly, in accordancewith embodiments of the present invention, the second conductor 1330 mayfurther include a second electrically-conducting-laminate stripconfigured to couple electrically with a second terminal of an adjacentprimary solar cell, for example, solar cell 1012 b, of a second adjacentsolar-cell sub-module, for example, solar-cell sub-module 1010 b, andelectrically coupled with a second adjacent diode. In an embodiment ofthe present invention, the second terminal of the adjacent primary solarcell of the second adjacent solar-cell sub-module may be a back side ofthe adjacent primary solar cell of the second adjacent solar-cellsub-module. Alternatively, the first terminal and the second terminalmay be configured as described in the preceding paragraphs, particularlyas described for FIGS. 11A-11D.

With reference now to FIG. 14, FIG. 10 and FIG. 12, in accordance withembodiments of the present invention, a combined plan and perspectiveview 1400 of a lead 1422 at a cut corner 1418 of the back glass 1414 ofa solar-cell module, for example, solar-cell module 1002, is shown. Thelead 1422 is shown here as a folded-over lead, without limitationthereto for embodiments of the present invention. An external-connectionmechanism of the solar-cell module is electrically coupled to the lead1422 at an edge region, for example, the cut corner 1418, of theplurality of edge regions of the protective structure of the solar-cellmodule, for example, solar-cell module 1002. The lead 1422 iselectrically coupled to the plurality of solar cells, for example,plurality 1010 of solar cells 1012 a-1017 a and 1012 b-1017 b. Asdescribed above, an external-connection mechanism of the solar-cellmodule may be selected from the group consisting of a wire, a connector,a lead, and a junction box, for example, external-connection mechanism1282 b as discussed here; and, an edge region may be selected from thegroup consisting of an edge of the solar-cell module and a corner of thesolar-cell module, where two edges may meet, for example, cut corner1418 as discussed here. The junction box, for example,external-connection mechanism 1282 b, of the solar-cell module, forexample, solar-cell module 1260 b, may be electrically coupled to aninterconnector, for example, interconnector 1288, through the lead 1422at the cut corner 1418 of the back glass 1414 of the solar-cell module1260 b. The lead 1422 may be intercoupled with appropriate lugs andinternal wiring to an external terminal junction of the junction box,for example, external-connection mechanism 1282 b, to provide thiselectrical coupling. The lead 1422 may be electrically coupled to theplurality of solar-cell sub-modules, for example, solar-cell sub-modules1010 a-1010 b, through a busbar (not shown) to which it is electricallycoupled. In embodiments of the present invention, the lead 1422 at theedge region, for example, cut corner 1418, of the plurality of edgeregions of the protective structure, for example, back glass 1414, mayinclude a copper lead.

With further reference to FIG. 14 and FIG. 10, in accordance withembodiments of the present invention, an edge 1424 of the lead 1422 atthe edge region, for example, cut corner 1418, of the protectivestructure, for example, front glass 1410 or back glass 1414, is locatedat a distance 1428 at least three-eighths of an inch from a nearestexternally accessible portion of the protective structure, for example,a joint 1426 between the external-connection mechanism (not shown) andthe front glass 1410 or back glass 1414, proximate to the edge of thelead. For example, the edge 1424 of the lead at the cut corner 1418 ofthe front glass 1410 or back glass 1414 may be located no closer thanthe distance 1428 of three-eighths of an inch from the joint 1426 thatan external-connection mechanism, for example, a junction box, makeswith the protective structure, for example, front glass 1410 or backglass 1414. Alternatively, the edge region may be a set-off notch (notshown) at an edge, for example, edges 1090, 1092, 1094 and 1096 as shownin FIG. 10, of the protective structure, rather than the cut corner1418, at which an external-connection mechanism, for example, a junctionbox might be disposed. It should be noted that the joint 1426 betweenthe outer surface of the junction box and the front glass 1410 or backglass 1414 is the nearest externally accessible portion of theprotective structure. The three-eighths of an inch distance 1428 betweenthis joint 1426 and the edge 1424 of the lead 1422 would provide a safedistance against the intrusive migration of water along the interfacebetween encapsulating adhesives used to attach the junction box to thefront glass 1410 or back glass 1414 and potting compounds used in thejunction box to electrically insulate the lead 1422. A distance shorterthan the three-eighths of an inch distance 1428 might cause anelectrical shock hazard for a potential difference above groundpotential, greater than or equal to 600 volts, on the lead 1422. Inaddition, the lead 1422 at the edge region, for example, cut corner1418, of the protective structure, for example, back glass 1414, mayinclude a portion of a busbar (not shown) attached to the plurality ofsolar cells, for example, the plurality 1010 of solar cells 1012 a-1017a and 1012 b-1017 b. As shown in FIG. 14, the front glass 1410 and theback glass 1414 that encapsulate the plurality of solar cells, forexample, the plurality 1010 of solar cells 1012 a-1017 a and 1012 b-1017b, provides a protective structure for the solar-cell module, forexample, solar-cell module 1002 as shown in FIG. 10. In accordance withembodiments of the present invention, the lead 1422 at the edge region,for example, cut corner 1418, is sealed between the front glass 1410 ofthe protective structure and a bottom portion, for example, back glass1414, of the protective structure with a first layer 1430 of polymericsealing material and a second layer 1432 of polymeric sealing material.The first layer 1430 of polymeric sealing material is disposed between alead-facing portion of the front glass 1410 and the lead 1422, and thesecond layer 1432 of polymeric sealing material is disposed between alead-facing portion of the bottom portion of the protective structureand the lead 1422. In embodiments of the present invention, thepolymeric sealing material may be a butyl-based sealing material. Thebottom portion of the protective structure may be a back glass 1414 butwithout limitation thereto for embodiments of the present invention; forexample, the bottom portion might be a non-transparent electricallyinsulating material other than glass. To the inventors' knowledge, theuse of this double application of polymeric sealing material to seal alead emerging from between the edges of the protective structure, forexample, front glass 1410 and back glass 1414, of a solar-cell modulehas not been used prior to its use in embodiments of the presentinvention.

With reference now to FIG. 15A, 15B and 15C, in accordance withembodiments of the present invention, various interconnection schemesfor interconnecting solar-cell modules having a variety ofexternal-connection mechanisms are shown. The external-connectionmechanisms are selected from the group consisting of junction boxes withan integrally attached male connector or an integrally attached femalereceptacle, and junction boxes with integrally attached leads having anattached male connector or an attached female receptacle. Theembodiments of the present invention described for FIGS. 15A, 15B and15C are but representative of embodiments of the present invention andare provided without limitation thereto, as other embodiments of thepresent invention for interconnecting two solar-cell modules are alsowithin the spirit and scope of embodiments of the present invention.

With reference now to FIG. 15A, in accordance with embodiments of thepresent invention, a plan view 1500A of a first junction box 1512 of afirst solar-cell module 1510 with a female receptacle 1514 a and asecond junction box 1522 of a second solar-cell module 1520 with a maleconnector 1524 a configured to allow interconnection with the firstsolar-cell module 1510 is shown. An interconnector (not shown) providedwith the male connector at one end and a female receptacle at the otherend may be used to interconnect first and second solar cell modules 1510and 1520. Junction boxes 1512 and 1522 may be mounted on the respectivecorners of their respective solar-cell modules 1510 and 1520 withadhesives, and the internal wiring and connections with respective leadsof their respective solar-cell modules 1510 and 1520 may be protectedfrom the environment with suitable electrical potting compounds. Inaccordance with embodiments of the present invention, the separationbetween first and second solar-cell modules 1510 and 1520, indicated bya gap between arrows 1550 and 1552, may also be minimized so as toreduce the length of an interconnector (not shown) between first andsecond solar-cell modules 1510 and 1520. Minimizing the separationbetween solar-cell modules improves solar-cell array efficiency byreducing wasted solar-collection space over the foot-print of thesolar-cell array, as well as reducing the parasitic series resistanceassociated with a long interconnector having to span a large separationbetween first and second solar-cell modules 1510 and 1520. Thus, inaccordance with embodiments of the present invention, the solar-cellmodules are arranged with a configuration to minimize wastedsolar-collection space within the solar-cell array such thatsolar-cell-array efficiency is greater than solar-cell-array efficiencyin the absence of the configuration.

With reference now to FIG. 15B, in accordance with embodiments of thepresent invention, a plan view 1500B of an interconnector 1526 a with amale connector 1524 b integrally attached to the second junction box1522 of the second solar-cell module 1520 and configured to allowinterconnection with the first junction box 1512 with the femalereceptacle 1514 a of the first solar-cell module 1510 is shown. Inaccordance with embodiments of the present invention, the interconnector1526 a between the second junction box 1522 of the second solar-cellmodule 1520 and the first junction box 1512 of the first solar-cellmodule 1510 may be a flexible interconnector. The interconnector 1526 abetween the second junction box 1522 of the second solar-cell module1520 and the first junction box 1512 of the first solar-cell module 1510may also be a rigid interconnector. The interconnector 1526 a may beintegrally attached to the second junction box 1522 of the secondsolar-cell module 1520 and configured to allow interconnection with thefirst junction box 1512 of the first solar-cell module 1510 such thatthe interconnector 1526 a has the male connector 1524 b to interconnectto the female receptacle 1514 a integrally attached to the firstjunction box 1512 of the first solar-cell module 1510.

With reference now to FIG. 15C, in accordance with embodiments of thepresent invention, a plan view 1500C of an interconnector 1526 b with afemale receptacle 1514 b integrally attached to the first junction box1512 of the first solar-cell module 1510, and of the interconnector 1526a with the male connector 1524 b integrally attached to the secondjunction box 1522 of the second solar-cell module 1520 and configured toallow interconnection with the first junction box 1512 is shown. Inaccordance with embodiments of the present invention, the interconnector1526 a attached to the second junction box 1522 of the second solar-cellmodule 1520 may be a flexible interconnector. Similarly, theinterconnector 1526 b attached to the first junction box 1512 of thefirst solar-cell module 1510 may be a flexible interconnector. Theinterconnector 1526 a attached to the second junction box 1522 of thesecond solar-cell module 1520 and the first junction box 1512 of thefirst solar-cell module 1510 may also be a rigid interconnector.Similarly, the interconnector 1526 b attached to the first junction box1512 of the first solar-cell module 1510 may be a rigid interconnector.The interconnectors 1526 a and 1526 b may be integrally attached totheir respective junction boxes 1522 and 1512 and configured to allowinterconnection of the first junction box 1512 of the first solar-cellmodule 1510 to the second junction box 1522 of the second solar-cellmodule 1520 through the interconnection of the male connector 1524 bwith the female receptacle 1514 b.

The foregoing descriptions of specific embodiments of the presentinvention have been presented for purposes of illustration anddescription. They are not intended to be exhaustive or to limit theinvention to the precise forms disclosed, and many modifications andvariations are possible in light of the above teaching. The embodimentsdescribed herein were chosen and described in order to best explain theprinciples of the invention and its practical application, to therebyenable others skilled in the art to best utilize the invention andvarious embodiments with various modifications as are suited to theparticular use contemplated. It is intended that the scope of theinvention be defined by the claims appended hereto and theirequivalents.

1. A solar-cell module comprising: a plurality of solar-cellselectrically coupled together; an in-laminate-diode assemblyelectrically coupled with said plurality of solar cells, saidin-laminate-diode assembly configured to prevent power loss; aprotective structure at least partially encapsulating said plurality ofsolar cells; and a plurality of external-connection mechanisms mountedto a respective plurality of edge regions of said protective structure,an external-connection mechanism of said plurality ofexternal-connection mechanisms configured to enable collection ofcurrent from said plurality of solar cells and to allow interconnectionwith at least one other external device.
 2. The solar-cell module ofclaim 1, wherein said external device is selected from the groupconsisting of a solar-cell module, an inverter, a battery charger, anexternal load, and an electrical-power-distribution system.
 3. Thesolar-cell module of claim 1, wherein an edge region of said pluralityof edge regions is selected from the group consisting of an edge of saidsolar-cell module, and a corner of said solar-cell module.
 4. Thesolar-cell module of claim 1, wherein a first external-connectionmechanism of said plurality of external-connection mechanisms of saidsolar cell module is disposed proximate to a second external-connectionmechanism of a second plurality of external-connection mechanisms ofsaid other solar-cell module.
 5. The solar-cell module of claim 1,wherein a first external-connection mechanism of said plurality ofexternal-connection mechanisms of said solar cell module is selectedfrom the group consisting of a wire, a connector, a lead, and a junctionbox.
 6. The solar-cell module of claim 1, wherein said in-laminate-diodeassembly comprises at least one in-laminate-diode sub-assembly, anin-laminate-diode sub-assembly comprising: a diode; a first conductorelectrically coupled to said diode; and a second conductor electricallycoupled to said diode.
 7. The solar-cell module of claim 6, wherein atleast one of said first and second conductors of said in-laminate-diodesub-assembly is configured as a heat sink to remove heat generated bysaid diode.
 8. The solar-cell module of claim 6, wherein saidin-laminate-diode sub-assembly further comprises anelectrically-insulating-laminate strip configured to allow access of atleast one of said first and second conductors to a solar cell of saidplurality of solar cells for electrically coupling with said solar cell.9. The solar-cell module of claim 6, wherein said in-laminate-diodesub-assembly further comprises at least one of said first and secondconductors structured to enable a laminated electrical connectionbetween at least one of said first and second conductors and anothercomponent of said solar-cell module.
 10. The solar-cell module of claim6, wherein said first conductor further comprises a firstelectrically-conducting-laminate strip configured to couple electricallywith a first terminal of an adjacent last solar cell of a first adjacentsolar-cell sub-module, and electrically coupled with a first adjacentdiode.
 11. The solar-cell module of claim 6, wherein said secondconductor further comprises a second electrically-conducting-laminatestrip configured to couple electrically with a second terminal of anadjacent primary solar cell of a second adjacent solar-cell sub-module,and electrically coupled with a second adjacent diode.
 12. Thesolar-cell module of claim 1, wherein said in-laminate-diode assemblycomprises at least one in-laminate-diode sub-assembly, saidin-laminate-diode sub-assembly comprising at least one diode configuredto by-pass current flow around a solar-cell sub-module to prevent powerloss.
 13. The solar-cell module of claim 1, wherein a firstexternal-connection mechanism of said plurality of external-connectionmechanisms of said solar-cell module and a second external-connectionmechanism of a second plurality of external-connection mechanisms ofsaid other solar-cell module are arranged on their respective solar-cellmodules to minimize a length of an interconnector between said firstexternal-connection mechanism and said second external-connectionmechanism.
 14. The solar-cell module of claim 1, wherein saidexternal-connection mechanism of said solar-cell module is electricallycoupled to a lead at an edge region of said plurality of edge regions ofsaid protective structure of said solar-cell module, said leadelectrically coupled to said plurality of solar cells.
 15. Thesolar-cell module of claim 14, wherein said lead at said edge region ofsaid plurality of edge regions of said protective structure comprises acopper lead.
 16. The solar-cell module of claim 14, wherein said lead atsaid edge region is sealed between a front glass of said protectivestructure and a bottom portion of said protective structure with a firstlayer of polymeric sealing material and a second layer of polymericsealing material, said first layer of polymeric sealing materialdisposed between a lead-facing portion of said front glass and saidlead, and said second layer of polymeric sealing material disposedbetween a lead-facing portion of said bottom portion and said lead. 17.The solar-cell module of claim 14, wherein an edge of said lead at saidedge region of said protective structure is located at a distance atleast three-eighths of an inch from a nearest externally accessibleportion of said protective structure proximate to said edge of saidlead.
 18. The solar-cell module of claim 14, wherein said lead at saidedge region of said protective structure comprises a portion of a busbarattached to said plurality of solar cells.
 19. The solar-cell module ofclaim 1 further comprising an integrated busbar-solar-cell-currentcollector comprising: a terminating busbar; and an integratedsolar-cell, current collector comprising: a plurality of integratedpairs of electrically conductive, electrically parallel trace portions,said plurality of integrated pairs of electrically conductive,electrically parallel trace portions configured both to collect currentfrom a terminating solar cell and to interconnect electrically to saidterminating busbar; wherein said plurality of integrated pairs ofelectrically conductive, electrically parallel trace portions isconfigured such that solar-cell efficiency is substantially undiminishedin an event that any one electrically conductive, electrically paralleltrace portion of said plurality of integrated pairs of electricallyconductive, electrically parallel trace portions is conductivelyimpaired.
 20. The solar-cell module of claim 19, wherein saidterminating busbar is folded under a back side of said terminating solarcell.
 21. The solar-cell module of claim 1, wherein said solar-cellmodule is arranged with a configuration to minimize wastedsolar-collection space within said solar-cell module such thatsolar-cell-module efficiency is greater than solar-cell-moduleefficiency in the absence of said configuration.
 22. The solar-cellmodule of claim 1, said solar-cell module further comprising: a firstsolar cell; at least a second solar cell; and an interconnect assemblydisposed above a light-facing side of an absorber layer of said firstsolar cell comprising: a trace comprising a plurality of electricallyconductive portions, said plurality of electrically conductive portionsconfigured both to collect current from said first solar cell and tointerconnect electrically to said second solar cell; wherein saidplurality of electrically conductive portions is configured such thatsolar-cell efficiency is substantially undiminished in an event that anyone of said plurality of electrically conductive portions isconductively impaired.
 23. The solar-cell module of claim 22, whereinsaid plurality of electrically conductive portions of said interconnectassembly is connected electrically in series to form a single continuouselectrically conductive line.
 24. The solar-cell module of claim 22,wherein said trace of said interconnect assembly is disposed in aserpentine pattern such that said interconnect assembly is configured tocollect current from said first solar cell and to interconnectelectrically to said second solar cell.
 25. The solar-cell module ofclaim 22, wherein said trace further comprises an electricallyconductive line comprising a conductive core and at least one overlyinglayer overlying said conductive core.
 26. The solar-cell module of claim22, wherein said trace further comprises an electrically conductive linecomprising a conductive core comprising nickel.
 27. The solar-cellmodule of claim 22, wherein said trace further comprises an electricallyconductive line comprising a conductive core comprising a materialhaving greater conductivity than nickel and an overlying layercomprising nickel.
 28. A solar-cell array comprising: a plurality ofelectrically coupled solar-cell modules, a solar cell module of saidplurality of electrically coupled solar-cell modules comprising: aplurality of solar-cells electrically coupled together; anin-laminate-diode assembly electrically coupled with said plurality ofsolar cells, said in-laminate-diode assembly configured to prevent powerloss; a protective structure at least partially encapsulating saidplurality of solar cells; and a plurality of external-connectionmechanisms mounted to a respective plurality of edge regions of saidprotective structure, an external-connection mechanism of said pluralityof external-connection mechanisms configured to enable collection ofcurrent from said plurality of solar cells and to allow interconnectionwith at least one other external device.
 29. The solar-cell array ofclaim 28, wherein said external device is selected from the groupconsisting of a solar-cell module, an inverter, a battery charger, anexternal load, and an electrical-power-distribution system.
 30. Thesolar-cell array of claim 28, wherein an edge region of said pluralityof edge regions is selected from the group consisting of an edge of saidsolar-cell module, and a corner of said solar-cell module.
 31. Thesolar-cell array of claim 28, wherein a first external-connectionmechanism of said plurality of external-connection mechanisms of saidsolar cell module is disposed proximate to a second external-connectionmechanism of a second plurality of external-connection mechanisms ofsaid other solar-cell module.
 32. The solar-cell array of claim 28,wherein a first external-connection mechanism of said plurality ofexternal-connection mechanisms of said solar cell module is selectedfrom the group consisting of a wire, a connector, a lead, and a junctionbox.
 33. The solar-cell array of claim 28, wherein saidin-laminate-diode assembly comprises at least one in-laminate-diodesub-assembly, an in-laminate-diode sub-assembly comprising: a diode; afirst conductor electrically coupled to said diode; and a secondconductor electrically coupled to said diode.
 34. The solar-cell arrayof claim 33, wherein at least one of said first and second conductors ofsaid in-laminate-diode sub-assembly is configured as a heat sink toremove heat generated by said diode.
 35. The solar-cell array of claim33, wherein said in-laminate-diode sub-assembly further comprises anelectrically-insulating-laminate strip configured to allow access of atleast one of said first and second conductors to a solar cell of saidplurality of solar cells for electrically coupling with said solar cell.36. The solar-cell array of claim 33, wherein said in-laminate-diodesub-assembly further comprises at least one of said first and secondconductors structured to enable a laminated electrical connectionbetween at least one of said first and second conductors and anothercomponent of said solar-cell module.
 37. The solar-cell array of claim33, wherein said first conductor further comprises a firstelectrically-conducting-laminate strip configured to couple electricallywith a first terminal of an adjacent last solar cell of a first adjacentsolar-cell sub-module, and electrically coupled with a first adjacentdiode.
 38. The solar-cell array of claim 33, wherein said secondconductor further comprises a second electrically-conducting-laminatestrip configured to couple electrically with a second terminal of anadjacent primary solar cell of a second adjacent solar-cell sub-module,and electrically coupled with a second adjacent diode.
 39. Thesolar-cell array of claim 28, wherein said in-laminate-diode assemblycomprises at least one in-laminate-diode sub-assembly, saidin-laminate-diode sub-assembly comprising at least one diode configuredto by-pass current flow around a solar-cell sub-module to prevent powerloss.
 40. The solar-cell array of claim 28, wherein a firstexternal-connection mechanism of said plurality of external-connectionmechanisms of said solar-cell module and a second external-connectionmechanism of a second plurality of external-connection mechanisms ofsaid other solar-cell module are arranged on their respective solar-cellmodules to minimize a length of an interconnector between said firstexternal-connection mechanism and said second external-connectionmechanism.
 41. The solar-cell array of claim 28, wherein saidexternal-connection mechanism of said solar-cell module is electricallycoupled to a lead at an edge region of said plurality of edge regions ofsaid protective structure of said solar-cell module, said leadelectrically coupled to said plurality of solar cells.
 42. Thesolar-cell array of claim 41, wherein an edge of said lead at said edgeregion of said protective structure is located at a distance at leastthree-eighths of an inch from a nearest externally accessible portion ofsaid protective structure proximate to said edge of said lead.
 43. Thesolar-cell array of claim 28 further comprising an integratedbusbar-solar-cell-current collector comprising: a terminating busbar;and an integrated solar-cell, current collector comprising: a pluralityof integrated pairs of electrically conductive, electrically paralleltrace portions, said plurality of integrated pairs of electricallyconductive, electrically parallel trace portions configured both tocollect current from a terminating solar cell and to interconnectelectrically to said terminating busbar; wherein said plurality ofintegrated pairs of electrically conductive, electrically parallel traceportions is configured such that solar-cell efficiency is substantiallyundiminished in an event that any one electrically conductive,electrically parallel trace portion of said plurality of integratedpairs of electrically conductive, electrically parallel trace portionsis conductively impaired.
 44. The solar-cell array of claim 43, whereinsaid terminating busbar is folded under a back side of said terminatingsolar cell.
 45. The solar-cell array of claim 28, wherein saidsolar-cell modules are arranged with a configuration to minimize wastedsolar-collection space within said solar-cell array such thatsolar-cell-array efficiency is greater than solar-cell-array efficiencyin the absence of said configuration.
 46. The solar-cell array of claim28, said solar-cell module of said solar-cell array further comprising:a first solar cell; at least a second solar cell; and an interconnectassembly disposed above a light-facing side of an absorber layer of saidfirst solar cell comprising: a trace comprising a plurality ofelectrically conductive portions, said plurality of electricallyconductive portions configured both to collect current from said firstsolar cell and to interconnect electrically to said second solar cell;wherein said plurality of electrically conductive portions is configuredsuch that solar-cell efficiency is substantially undiminished in anevent that any one of said plurality of electrically conductive portionsis conductively impaired.
 47. The solar-cell array of claim 46, whereinsaid plurality of electrically conductive portions of said interconnectassembly is connected electrically in series to form a single continuouselectrically conductive line.
 48. The solar-cell array of claim 46,wherein said trace further comprises an electrically conductive linecomprising a conductive core and at least one overlying layer overlyingsaid conductive core.
 49. The solar-cell array of claim 46, wherein saidtrace further comprises an electrically conductive line comprising aconductive core comprising nickel.
 50. The solar-cell array of claim 46,wherein said trace further comprises an electrically conductive linecomprising a conductive core comprising a material having greaterconductivity than nickel and an overlying layer comprising nickel.
 51. Aphotovoltaic-convertor module comprising: a plurality of photovoltaicconvertors electrically coupled together; an in-laminate,current-shunting assembly means for by-passing current flow, saidin-laminate, current-shunting assembly means electrically coupled withsaid plurality of photovoltaic convertors, said in-laminate,current-shunting assembly means configured to prevent power loss; aprotective structure at least partially encapsulating said plurality ofphotovoltaic convertors; and a plurality of junction-enclosure means forprotecting and electrically isolating electrical connections, saidplurality of junction-enclosure means mounted to a respective pluralityof edge regions of said protective structure, a junction-enclosure meansof said plurality of junction-enclosure means configured to enablecollection of current from said plurality of photovoltaic convertors andto allow interconnection with at least one other external device.
 52. Aphotovoltaic-convertor array comprising: a plurality of electricallycoupled photovoltaic-convertor modules, a photovoltaic-convertor moduleof said plurality of electrically coupled photovoltaic-convertor modulescomprising: a plurality of photovoltaic convertors electrically coupledtogether; an in-laminate, current-shunting assembly means for by-passingcurrent flow, said in-laminate, current-shunting assembly meanselectrically coupled with said plurality of photovoltaic convertors,said in-laminate, current-shunting assembly means configured to preventpower loss; a protective structure at least partially encapsulating saidplurality of photovoltaic convertors; and a plurality ofjunction-enclosure means for protecting and electrically isolatingelectrical connections, said plurality of junction-enclosure meansmounted to a respective plurality of edge regions of said protectivestructure, a junction-enclosure means of said plurality ofjunction-enclosure means configured to enable collection of current fromsaid plurality of photovoltaic convertors and to allow interconnectionwith at least one other external device.